Roller Crusher Tooth Segment Wear Resistance Upgrade

Project Background

A Brazilian customer operating roller crushers in a high-abrasion environment was facing severe wear problems on the tooth segments of their crushers. The original tooth segments were manufactured by integral casting, which resulted in rapid wear, frequent replacement, and high maintenance costs.

To improve the wear resistance and extend service life without redesigning the entire component, the customer approached TSR for a material and surface treatment upgrade solution.

Challenges

• Extremely abrasive working conditions
• Fast wear rate of the original cast tooth segments
• Frequent shutdowns for replacement
• High spare parts consumption and maintenance cost

The customer required a cost-effective solution with significant improvement in wear performance.

TSR Solution
After detailed analysis of the working conditions and wear patterns, TSR proposed a targeted upgrade solution:

• Retain the original base material and structure
• Apply high-chromium wear-resistant overlay welding on the working surface of the tooth segments
• Optimize overlay thickness and distribution according to wear zones

The high-chromium alloy overlay provides excellent resistance to abrasion, impact, and fatigue, making it particularly suitable for heavy-duty crushing applications.

Technical Parameters (Reference Data)

• Overlay material: High-chromium alloy
• Hardness of overlay layer: HRC 58–62
• Overlay thickness: 6–10 mm (customized by wear zone)
• Typical service life improvement: +120% to +180%

Performance Results
After implementation, the upgraded tooth segments showed outstanding performance in site operation:

• Service life extended by approximately 2.5 times
• Replacement frequency reduced by over 60%
• Annual spare parts cost reduced by around 35–40%
• Equipment downtime significantly minimized

The customer expressed high satisfaction with both the technical performance and economic benefits.

Project Value
This project demonstrates TSR’s strong capability in wear-resistant material engineering and customized upgrade solutions for crusher wear parts.
By combining advanced surface treatment technologies with practical operating experience, TSR helps customers maximize equipment life, reduce operating costs, and improve overall production efficiency.