Hi Chrome Castings
Welcome to Bhanu Special Castings Pvt. Ltd. – your trusted partner for ultra-hard Hi Chrome castings in Vijayawada and across India. As a specialized high-chromium iron foundry, we manufacture extreme wear-resistant castings with 15-30% chromium content, achieving hardness levels of 700+ HB for mining grinding media, cement mill liners, crusher wear parts, and slurry pump components operating in the most abrasive environments.
Hi Chrome castings are advanced wear-resistant alloys where high chromium (15-30%) combines with carbon (2.5-3.5%) to form massive chromium carbide (Cr7C3) particles in a martensitic or austenitic matrix, delivering exceptional abrasion resistance—up to 10-15x better than mild steel and 3-4x better than manganese steel in pure abrasive wear conditions. These castings excel in grinding, crushing, and slurry handling applications where metal-to-ore/rock contact causes severe material loss.
Our Hi Chrome castings deliver unmatched performance including extreme hardness (600-750 HB depending on grade), outstanding abrasion resistance in pure sliding wear, good corrosion resistance in acidic slurries, and heat treatment flexibility for optimized toughness. Manufactured to ASTM A532, EN 12513 standards in Classes I, II, III, these castings serve as grinding balls and media, mill liners and lifters, crusher blow bars and mantles, slurry pump impellers and volutes, and coal pulverizer rolls. With advanced heat treatment and comprehensive hardness testing, every casting meets the demanding requirements of mining, cement, and power industries.
Our Product Range
We manufacture ultra-hard high-chrome castings engineered for extreme abrasive wear conditions:
- Grinding Media Balls (25–125 mm), cylpebs, and rods for SAG and ball mill applications.
- Mill Liners & Lifters Wear liners and lifter bars for SAG, AG, and ball mills.
- Crusher Wear Parts Blow bars, mantles, concaves, and jaw plates for crushing systems.
- Slurry Pump Components Impellers, volutes, throat bushes, and liners for abrasive slurries.
- Coal Pulverizer Rolls Grinding rolls, segments, and tables for thermal power plants.
- Cement Mill Parts Grinding media, diaphragms, and separators for cement grinding.
- Dredge Pump Parts Impellers, cutters, and suction liners for dredging operations.
- Custom Hi Chrome Castings Application-specific wear parts manufactured to customer specifications.
Weight Range: 0.5 kg to 6000 kg | Hardness: 600–750 HB
Industry Applications
Our high-chrome castings serve extreme wear environments across:
- Mining & Mineral Processing Gold, copper, iron ore, and coal grinding operations.
- Cement Manufacturing Raw material grinding and clinker processing systems.
- Power Generation Coal pulverization, ash handling, and FGD applications.
- Aggregate & Quarrying Rock crushing and sand production operations.
- Dredging Operations Sand pumping, seabed mining, and channel deepening.
- Chemical Processing Abrasive slurry handling and transfer systems.
- Steel Mills Slag processing and heavy material handling operations.
- Recycling E-waste, metal scrap, and glass recycling equipment.
Hi Chrome castings contain 15-30% chromium and 2.5-3.5% carbon, forming massive chromium carbide (Cr₇C₃) particles that constitute up to 30% of the microstructure. These extremely hard carbides (1500-1800 HV) embedded in a martensitic or austenitic matrix provide exceptional abrasion resistance—making Hi Chrome the material of choice for mining grinding media, cement mill liners, crusher wear parts, and slurry pumps where metal surfaces continuously slide against abrasive ore, rock, or mineral slurries.
Advanced Hi Chrome Casting Process
At Bhanu Special Castings, our Hi Chrome foundry employs precise chromium and carbon control with optimized heat treatment to produce ultra-hard castings with maximum abrasion resistance and controlled toughness.
1. Design & Pattern Making
Wear part geometry optimization, proper gating for carbide distribution, dimensional allowances for Hi Chrome shrinkage characteristics.
2. Controlled Chromium Melting
Electric induction furnace with precise Cr (15-30%) and C (2.5-3.5%) addition, temperature control to prevent carbide agglomeration, spectroscopic analysis for composition verification.
3. Casting & Solidification
Controlled pouring to promote eutectic carbide formation, optimized cooling rates for carbide distribution, sand removal and initial cleaning.
4. Heat Treatment
Destabilization at 950-1050°C to transform retained austenite, tempering at 200-250°C for stress relief, achieving target hardness 600-750 HB.
5. Machining & Finishing
Specialized tooling for ultra-hard material machining, grinding to final dimensions, surface preparation for installation.
6. Hardness & Quality Testing
Brinell hardness mapping (multiple locations), microstructure examination for carbide distribution, drop test for toughness verification.
Heat Treatment for Maximum Wear Resistance
Heat treatment is critical for Hi Chrome castings to transform retained austenite to martensite, maximizing hardness while controlling toughness for impact resistance in grinding/crushing applications:
| Heat Treatment | Temperature & Process | Purpose & Benefits | Resulting Hardness |
|---|---|---|---|
| As-Cast | No treatment (slow cooling) | High retained austenite, lower hardness | 500-600 HB (slurry pump applications) |
| Destabilization | 950-1050°C, air cool | Transform retained austenite to martensite | 650-700 HB (grinding media, mill liners) |
| Destabilization + Temper | 950-1050°C + 200-250°C temper | Maximum hardness with controlled toughness | 700-750 HB (crusher blow bars, high-impact) |
| Sub-Zero Treatment | -80°C cryogenic + tempering | Further austenite transformation, ultimate hardness | 750+ HB (premium grinding media) |
Key Properties & Benefits of Hi Chrome Castings
Hi Chrome castings deliver exceptional abrasion resistance through the formation of massive chromium carbide (Cr₇C₃) particles, which are significantly harder than the surrounding matrix. This structure provides superior wear life in applications dominated by pure sliding abrasion.
- Extreme Hardness Achieves hardness levels of 600–750 HB depending on chromium content and heat treatment, with chromium carbides reaching 1500–1800 HV—ideal for grinding media and mill liners.
- Outstanding Abrasion Resistance Provides 10–15 times longer wear life than mild steel and 3–4 times better performance than manganese steel in ball and SAG mills where sliding abrasion dominates.
- Good Corrosion Resistance High chromium content offers resistance to acidic slurries in the pH range of approximately 3–11, common in mineral processing and FGD systems.
- Moderate Impact Resistance Lower toughness than manganese steel, making Hi Chrome best suited for low-impact or pure abrasion applications. Crusher grades are optimized to handle moderate impact conditions.
- Heat Resistance Maintains structural stability and wear performance at temperatures up to 400–500°C, suitable for cement clinker grinding and coal pulverization.
- Cost-Effective Wear Life Although initial cost is higher than manganese steel, Hi Chrome delivers 3–4 times longer service life, reducing grinding media consumption and overall mill downtime.
Hi Chrome castings excel in pure abrasive wear and sliding contact applications but are more brittle than manganese steel. Select Hi Chrome for ball and SAG mills, slurry pumps, and cement grinding, while manganese steel remains the better choice for high-impact jaw and cone crushers.
Typical Composition & Properties (ASTM A532 Hi Chrome Classes)
| Element / Property | Class I (15% Cr) | Class II (20% Cr) | Class III (25-28% Cr) |
|---|---|---|---|
| Chromium (Cr) | 11-14% | 19-23% | 23-30% |
| Carbon (C) | 2.0-3.3% | 2.0-3.3% | 2.3-3.6% |
| Manganese (Mn) | 0.5-2.0% | 0.5-2.0% | 0.5-1.5% |
| Silicon (Si) | 0.5-1.5% | 0.5-1.5% | 0.5-1.5% |
| Molybdenum (Mo) | 0-3% | 0-3% | 0-3% |
| Carbide Volume | 15-20% | 20-25% | 25-35% |
| Hardness (Heat Treated) | 600-650 HB | 650-700 HB | 700-750 HB |
| Typical Applications | Crusher parts, pump liners | Mill liners, grinding media | Premium grinding media, cement mills |
Higher Cr content = more carbides = greater hardness/abrasion resistance but lower toughness. Mo addition (1-3%) improves matrix toughness for crusher applications.
Customization and Quality Assurance
We provide fully customized Hi Chrome castings engineered to your exact wear conditions, from chromium content selection (15-30%) and heat treatment optimization to geometry design for maximum grinding/crushing efficiency. Our team in Vijayawada ensures every component delivers maximum wear life in your specific application.
Customization Capabilities
- Chromium content (15-30%) per abrasion severity
- Optimized heat treatment (destabilization, tempering, cryo)
- Geometry optimization for grinding efficiency
- Mo addition for impact-prone applications
- Size range: 25mm grinding balls to 6-ton mill liners
- Drop testing for crusher blow bars
Quality Testing & Certifications
- Chemical Analysis Verification of chromium, carbon, manganese, and molybdenum content for each heat to ensure grade compliance.
- Hardness Testing Multi-point Brinell hardness mapping performed to confirm hardness levels between 600–750 HB across wear zones.
- Microstructure Analysis Metallographic examination to evaluate chromium carbide distribution and retained austenite levels.
- Impact / Drop Testing Drop and impact tests conducted for crusher-grade components to assess toughness under service conditions.
- Dimensional Inspection Precision inspection of critical dimensions to ensure proper fit-up in mills and crushing equipment.
- ASTM A532 Compliance Full material certification and traceability provided in accordance with ASTM A532 standards.
Every Hi Chrome casting undergoes rigorous testing including spectroscopic chemical analysis, multiple-point hardness testing, microstructure examination for carbide distribution, and dimensional verification. Our quality protocol guarantees compliance with ASTM A532, EN 12513, AS 2027 standards.
Grades and Applications of High Chrome Castings
Our High Chrome castings are produced in multiple grades to cater to diverse industrial needs. Common grades include ASTM A532, AS 2027 , EN 12513, EN 100Cr6 (1.3505), EN 1.4034 (X46Cr13), EN 1.4112 (X90CrMoV18), EN 1.4016 (X6Cr17) , and EN 1.4568 (X2CrNiMo18-14-3).
These castings are widely adopted in industries where extreme wear, corrosion, and impact occur. Key applications include:
- Mining & Mineral Processing: Grinding media, crusher parts, slurry pump components.
- Power Generation: Coal pulverizer rolls, boiler tubes, ash handling systems.
- Cement Industry: Grinding media and wear liners for cement mills.
- Oil & Gas Industry: Mud pump liners, drilling tools, and valve components.
- Industrial Pumps: Abrasive fluid handling components.
- Grinding Equipment: Mill liners, media, and plates.
- High Wear Machinery Parts: Crusher and pulverizer components.
- Custom Castings: Special grades and dimensions as per client requirements.
| Grade | Properties | Common Applications |
|---|---|---|
| ASTM A532 / EN 12513 | High hardness, excellent abrasion resistance, moderate corrosion resistance | Grinding media, crusher liners, slurry pump components |
| EN 100Cr6 (1.3505) / EN 1.4034 (X46Cr13) | High-carbon, chromium alloy, excellent wear resistance, good corrosion resistance | Coal pulverizer rolls, boiler tubes, valve parts, high-wear industrial components |
Why Choose Bhanu Special Castings for Hi Chrome?
With specialized expertise in ultra-hard Hi Chrome castings for mining, cement, and power industries, we deliver consistent hardness, optimal carbide distribution, and maximum wear life. Here's why we're the trusted choice:
Wear Resistance Experts
Decades of experience manufacturing grinding media and mill liners delivering 3-4x longer wear life than standard materials.
Advanced Heat Treatment
Large-capacity destabilization furnaces with precise temperature control ensuring consistent 700+ HB hardness throughout.
Metallurgical Lab
In-house microstructure analysis for carbide distribution, retained austenite measurement, and hardness verification.
Mining Industry Specialist
Trusted supplier to major gold, copper, iron ore, and coal mines across India with proven field performance.
Hardness-Toughness Balance
Customized Cr% and Mo addition to optimize for your specific application—pure abrasion vs. impact-abrasion.
Technical Partnership
Wear analysis, material selection guidance, mill liner design support, and field performance tracking.
Frequently Asked Questions (FAQ)
Ready for Extreme-Duty Castings?
Get in touch with our Vijayawada team for custom designs, fast quotes, and ISO-certified quality you can trust.
Product Gallery
