Material
Grades of castings.
Every casting we make falls into one of these four grades. The right one is decided by a single question — what is in your feed. Pick a grade to see what we cast in it.
Grade 1 of 4
Manganese Steel Wear Parts
Melco manganese wear parts are a relatively low-cost option, offering good wear life, and are ideally suited for high impact applications where tramp metal or uncrushable objects are included in the feed material.
The initial hardness is around 200/230 Brinell, or 20/21 HRC. After work hardening, the hardness can go up to 500 Brinell or 50 HRC. The deeper layers, not yet hardened, thereby provide great toughness to this steel. The depth and hardness depend on the application and type of manganese steel — the hardened layer penetrates to a depth of approximately 10 mm.
Available in standard and premium grade manganese steel.
- Hardness200/230 HB as cast, up to 500 HB work-hardened
- SuitsHigh impact, tramp metal in the feed
Shredder HammersELV and scrap shredder duty
Shredder HammersManganese steel, several sizes
Shredder Hammers Ready for DespatchStandard and premium manganese
Kleemann Reiner Blow BarsManganese grade 6/7 for CDR
CDR Blow BarsManganese steelReady for DespatchCast, finished and shippedGrade 2 of 4
Hi-Chrome White Iron Wear Parts
Melco chrome white iron wear parts are ideally suited to applications with high abrasion, offering cost effective wear life. They are not suited to applications where tramp metal or uncrushable objects are included in the feed material.
In high chrome iron the carbon is chemically bonded in the form of chrome carbide. The wear resistance of chrome steel is based on these hard chrome carbides of the hard matrix, whereby the movement is hindered by offsets, which provides for a degree of strength but at the same time less toughness.
To prevent the material from becoming too brittle the blow bars are heat treated. It must thereby be observed that the temperature and annealing time parameters are adhered to. Chrome iron typically has a hardness of 56 to 61 HRC and a very low impact strength. To prevent breakage of high chrome blow bars, there may not be any unbreakable elements in the feed material.
Available in medium and high chrome grades.
- Hardness56 – 61 HRC
- SuitsHigh abrasion, no tramp metal
Blow BarsHigh chrome, martensitic and manganese
SBM Blow BarsHigh chrome white iron
Hazemag Blow BarsHigh chromiumHazemag Blow BarHigh chromium
Hartl / SBM Blow BarHigh chrome
Mixer Bottom Wear PlateHigh chrome / Ni-HardGrade 3 of 4
Martensitic Steel Wear Parts
Melco martensitic wear parts are considered ideal in applications where the feed material varies. Offering impact resistance similar to manganese steel with improved wear properties, they also demonstrate good resistance to abrasive gouging.
Blow bars made of martensitic steel are used in primary or secondary crushing applications where high wear or impact both exist. In these applications the manganese steel is not suitable for its low hardness, whereas chromium white iron is not durable for impact.
- HardnessBetween manganese and high chrome
- SuitsFeed material that varies
Kleemann Blow BarMartensitic steel
Impactor Blow BarsMartensitic steel
Blow BarsMachined and palletised
Tesab Blow BarCast, machined and marked in-houseGrade 4 of 4
Heat Resistant Steel Castings (HRCS)
Melco Precisions makes quality heat resistant steel castings like stoking, travelling and reciprocating grates for waste-to-energy plants, incinerators and boilers, and grate bars for iron ore pelletisation plants.
Parts in this duty do not wear out the way a crusher liner does — they fail by creep, thermal fatigue and oxidation. The bar sags, cracks across its section, or scales away until it loses its profile. The alloy chemistry and the soundness of the casting are what decide how long it lasts.
We are an OEM supplier to KMW Energi (Sweden), now Jernforsen, and have supplied Kudremukh Iron Ore Company, Essar Steel and JSW.
- HardnessSpecified for creep and oxidation, not hardness
- SuitsSustained heat, thermal cycling
W2E Grate BarsHeat resistant high chrome steel
Boiler Grate BarsIncinerator and W2E dutyReciprocating Step Grate BarCast to drawingPellet Plant Grate BarsIron ore induration machines
HRCS CatalogueOur heat resistant castings rangeAnalytical specification
Typical composition of our wear resistant alloy castings.
Our published MELCO LOY grades, with the ASTM A-532, BS 4844 and IS 276-2000 equivalents. Tell us your duty and we will name the grade.
| MELCO LOY No. | T.C. % | Si % | Mn % | Ni % | Cr % | Mo % | Hardness (BHN) | ASTM Spec. | BS 4844 |
|---|---|---|---|---|---|---|---|---|---|
| MPW-1 | 2.8–3.6 | 0.8 max | 2.0 max | 3.3–5.0 | 1.4–4.0 | 1.0 max | 550–600 | A-532-IA | 2A |
| MPW-2 | 2.4–3.0 | 0.8 max | 2.0 max | 3.3–5.0 | 1.4–4.0 | 1.0 max | 550–600 | A-532-IB | 2B |
| MPW-3 | 2.5–3.7 | 0.8 max | 2.0 max | 4.0 max | 1.0–2.5 | 1.0 max | 550–600 | A-532-IC | — |
| MPW-4 | 2.5–3.6 | 2.0 max | 2.0 max | 4.5–7.0 | 7.0–11.0 | 1.5 max | 550–600 | A-532-ID | 2C, 2D, 2E |
| MPW-5 | 2.0–3.3 | 1.5 max | 2.0 max | 2.5 max | 11.0–14.0 | 3.0 max | 600–650 | A-532-IIA | 3F / 3G |
| MPW-6 | 2.0–3.3 | 1.5 max | 2.0 max | 2.5 max | 14.0–18.0 | 3.0 max | 600–650 | A-532-IIB | 3A |
| MPW-7 | 2.8–3.6 | 1.0 max | 2.0 max | 0.5–1.0 | 14.0–18.0 | 2.3–3.5 | 600–650 | A-532-IIC | 3B |
| MPW-8 | 2.0–3.3 | 1.0–2.2 | 2.0 max | 2.5 max | 18.0–23.0 | 3.0 max | 600–700 | A-532-IID | 3C |
| MPW-9 | 2.6–3.2 | 1.0 | 2.0 max | 1.5–2.0 | 18.0–23.0 | 1.0–2.0 | 600–700 | A-532-IIE | — |
| MPW-10 | 2.0–3.3 | 1.5 max | 2.0 max | 2.5 max | 23.0–30.0 | 3.0 max | 600–700 | A-532-IIIA | 3D |
| MELCO LOY No. | C % | Mn % | Si % | S % | P % | Cr % | Mo % | Ni % | IS 276-2000 Grade |
|---|---|---|---|---|---|---|---|---|---|
| MPW-11 | 1.05–1.35 | 11.0–14.0 | 1.0 | 0.08 | 0.025 | — | — | — | 1 |
| MPW-12 | 0.90–1.05 | 11.5–14.0 | 1.0 | 0.08 | 0.025 | — | — | — | 2 |
| MPW-13 | 1.05–1.35 | 11.5–14.0 | 1.0 | 0.08 | 0.025 | 1.5–2.5 | — | — | 3 |
| MPW-14 | 0.70–1.30 | 11.5–14.0 | 1.0 | 0.08 | 0.025 | — | — | 3.0–5.0 | 4 |
| MPW-15 | 1.05–1.45 | 11.5–14.0 | 1.0 | 0.08 | 0.025 | — | 1.8–2.1 | — | 5 |
| MPW-16 | 1.05–1.35 | 16.0–19.0 | 0.30–0.90 | 0.08 | 0.025 | — | — | — | 6 |
| MPW-17 | 1.05–1.35 | 16.0–19.0 | 0.30–0.90 | 0.08 | 0.025 | 1.5–2.5 | — | — | 7 |
Hardness is quoted in BHN. Manganese steel is supplied in standard and premium grades — the grade 6 and 7 rows (MPW-16, MPW-17) are the higher-manganese grades used for demolition recycling blow bars, where rebar and tramp metal reach the chamber.
We cast to your drawing, pattern or worn sample.
In-house from R&D and design right up to final finishing.
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