Particle reinforced Hadfield steel

Abstract

This study investigates the development of reinforced Hadfield steel composites aimed at improving
hardness and wear resistance for applications subjected to serve impact and abrasion. Hadfield steel,
although known for its excellent toughness and work hardening capability, exhibits relatively low initial
hardness, which limits its performance in high wear environments. To address this limitation, ceramic
reinforcement in the form of titanium carbide (TiC) and tungsten carbide (WC) were introduced using a
combination of powder metallurgy and casting techniques.
Powder mixtures were homogenized using Turbula mixing, compacted into inserts, cast with molten
Hadfield steel and heat treated.
Microstructural analysis revealed fine, uniformly distributed particles improved hardness and load
transfer, while coarse particles and agglomerates led to stress concentration and cracking. TiC showed
better dispersion and interfacial bonding compared to WC, which exhibited segregation and weaker
interfaces. Defects such as porosity and secondary phase transformation further affected performance.

Popular Abstract

DIVISION OF PRODUCTION AND MATERIALS ENGINEERING | MASTER THESIS | LUND UNIVERSITY
Can a crusher tooth last three times longer?
Crusher components are subjected to continuous wear every day, which affects cost and maintenance. This project asked
whether locking hard ceramic particles inside the steel from the start could change that.
The problem
Cone crushers are central to many mining operations, where they process rocks continuously for long periods. The steel here
in this wears rapidly in abrasive service. The alloy typically used, Hadfield steel, is genuinely tough. It gets harder as it absorbs
impacts in service. But it takes time to reach that hardened state, and in the meantime, material can already be lost as fine
metallic wear debris .In applications with limited impact , the steel may never harden enough to provide its full benefit.
The fix we tested
The objective was to avoid relying solely on service-induced hardening. Instead of allowing the steel to gain hardness gradually
during operation, the study aimed to introduce hardness directly into the material by incorporating ceramic particles before the
component was placed in service. Two reinforcement candidates were investigated: titanium carbide (TiC) and tungsten carbide
(WC). Both materials are widely used in cutting-tool applications and are characterized by very high hardness. The main
question was whether these particles could withstand the casting process and form a sufficiently strong bond with the
surrounding steel matrix.
How we made it
Ceramic and graphite powders were blended in a Turbula mixer, pressed into solid inserts, and placed inside moulds. Molten
Hadfield steel at over 1400 degrees was poured around them. At this temperature, surface reactions may take place between
the particles and the surrounding melt. After cooling, the samples were heat treated and cut open for microscopic analysis.
What we found
Hardness went from 294 HV in the base steel to 993 HV in the reinforced zone. This represents substantial increase in hardness
compared with the base steel. TiC came out ahead, which was not obvious going in since WC is actually the harder material of
the two at around 2400 HV versus 2000 HV.
WC is almost twice as dense as molten steel. It sinks. It shows limited to no chemical affinity towards Iron , so there is no
bonding at the interface. TiC sits at a more compatible density and reacts with the melt, anchoring itself into the matrix. That
is why it won. Crack paths through the composite also confirmed better toughness: instead of travelling straight, cracks
deflected around particles, taking a longer route and consuming more energy to get there.
Why it matters
A component that starts service at 993 HV instead of 294 HV has a very different wear trajectory. Fewer replacements means
less manufacturing, less material, less energy. The work also flags a next step worth pursuing: mixing TiC with niobium carbide
to form a hybrid system that could solve some of the remaining defect problems and push performance further.
Mini Dictionary
Hadfield steel : a high-manganese steel that hardens under impact. Tough from day one, but not very hard until it has been hit a lot.
TiC / WC : titanium carbide and tungsten carbide. Both are ceramics used in cutting tools. Very hard, very brittle on their own.
Vickers hardness (HV): a standard way to measure how much a material resists being dented. Higher is harder.
Crack deflection : when a crack is forced to go around a hard particle instead of through it. Longer path, more energy, tougher
material.

• author: Inamdar, Shrivishnu Anand and Tendulkar, Shaunak Ramkrishna
• supervisor: Christina Windmark
• organization: Production and Materials Engineering
• course: MMTM05 20261
• year: 2026
• type: H2 - Master's Degree (Two Years)
• subject: Technology and Engineering
• keywords: Hadfield steel, Turbula mixing, interfacial bonding, Metal Matrix composites
• other publication id: LUTMDN/(TMMV-5398)/1-37/2026
• language: English
• id: 9235941
• date added to LUP: 2026-06-12 13:55:36
• date last changed: 2026-06-12 13:55:36