Customer Case ｜Jaw Plates with Inlaid High Chromium Wear-Resistant Blocks

A large mining operation operates a primary jaw crusher for hard rock crushing under continuous and high-impact conditions. The processed material features high hardness and strong abrasiveness, with a Mohs hardness of 6–7, resulting in severe wear on conventional jaw plates.

Under the original configuration, standard high-manganese steel jaw plates were used. Due to the combined effects of high impact load and abrasive wear, the jaw plates showed rapid material loss in high-wear zones, with an average service life of approximately 2,600 operating hours, leading to frequent shutdowns and increased maintenance costs.

After a detailed assessment of the actual site conditions, including ore hardness, feed size distribution, impact intensity, and wear profile of the jaw plates, TSR applied its proprietary technology:
inlaid high chromium wear-resistant blocks on a high manganese steel base, specifically designed for jaw crusher jaw plates.

This exclusive composite structure allows:

• High chromium blocks to provide excellent abrasion resistance in critical wear areas, while
• The high manganese steel base delivers high impact toughness and work-hardening capability, ensuring structural integrity under heavy loads.

The customized jaw plates were installed in 2023 under identical operating parameters to the previous configuration.

According to on-site operational data:

• The service life of TSR jaw plates reached approximately 3,800–4,000 operating hours,
• Representing a service life increase of over 45% compared with conventional high-manganese steel jaw plates,
• Jaw plate replacement frequency was reduced from 4 times per year to 2–3 times per year,
• Unplanned downtime related to jaw plate wear was reduced by more than 25%.

Throughout the entire service period, the jaw plates exhibited uniform wear, with no abnormal failures such as block detachment, cracking, or premature breakage.

This case clearly demonstrates the advantages of TSR’s proprietary inlaid wear technology for jaw crusher applications, providing:

• Targeted wear protection for high-abrasion zones
• Improved service life under combined impact and abrasion conditions
• Lower total cost of ownership for mining and aggregates operations

TSR continues to develop application-specific, engineered wear solutions, helping customers achieve safer, more efficient, and more cost-effective crushing operations.

Inlaid high chromium wear-resistant block on a high manganese steel base