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<p>Mineral extraction and processing equipment, particularly tricone drill bits and cone crushers, play crucial roles in rock fragmentation for blasting and ore comminution for grinding in mining. Understanding their operation, material composition, and operating environment is essential for analysing failure modes and mechanisms to propose wear resistant materials and remanufacturing strategies for prolonging their life span to enhance their efficiency. This review examined the operation, material composition, and operating environment of drilling and crushing components, characterising their failure modes and mechanisms to identify mitigation measures. Subsequently, wear-resistant materials tailored to predominant failure modes and suitable remanufacturing techniques are discussed. A techno-economic analysis methodology was presented to review the selected material and the remanufacturing technique, comparing their economic feasibility with replacement options. The novelty of this study is that it integrates failure analysis, remanufacturing methods and a techno-economic evaluation into a practical remanufacturing framework that the mining industry can follow to assess and remanufacture failed components. A composite of H13 matrix with TiC reinforcement is proposed for the steel body of the tricone drill bit, while Rockit 606 powder was recommended for the cone crusher mantle liner. Hybrid remanufacturing was suggested, employing gas tungsten arc welding (GTAW) for the tricone drill bit body and submerged flux core arc welding (FCAW-S) for the mantle liner. The direct energy deposition technique (laser cladding) is proposed to deposit the selected wear-resistant material as a protective coating, offering a significantly improved lifespan. The goal is to improve mining efficiency, mitigate downtime, optimize performance, coat, productivity and support sustainable remanufacturing practices.</p>

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Failure analysis and remanufacturing techniques in drilling and crushing equipment in mining industries: a review

  • 期刊论文

  • 发表日期：

    2026年3月21日

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  • E. O. Adefila,
  • B. Nabifo,
  • E. O. Olakanmi,
  • R. V.S. Prasad,
  • T. P. Leso,
  • K. Setswalo,
  • A. Botes,
  • R. Ndeda,
  • S. L. Pityana,
  • N. Y. Ematang

摘要

Mineral extraction and processing equipment, particularly tricone drill bits and cone crushers, play crucial roles in rock fragmentation for blasting and ore comminution for grinding in mining. Understanding their operation, material composition, and operating environment is essential for analysing failure modes and mechanisms to propose wear resistant materials and remanufacturing strategies for prolonging their life span to enhance their efficiency. This review examined the operation, material composition, and operating environment of drilling and crushing components, characterising their failure modes and mechanisms to identify mitigation measures. Subsequently, wear-resistant materials tailored to predominant failure modes and suitable remanufacturing techniques are discussed. A techno-economic analysis methodology was presented to review the selected material and the remanufacturing technique, comparing their economic feasibility with replacement options. The novelty of this study is that it integrates failure analysis, remanufacturing methods and a techno-economic evaluation into a practical remanufacturing framework that the mining industry can follow to assess and remanufacture failed components. A composite of H13 matrix with TiC reinforcement is proposed for the steel body of the tricone drill bit, while Rockit 606 powder was recommended for the cone crusher mantle liner. Hybrid remanufacturing was suggested, employing gas tungsten arc welding (GTAW) for the tricone drill bit body and submerged flux core arc welding (FCAW-S) for the mantle liner. The direct energy deposition technique (laser cladding) is proposed to deposit the selected wear-resistant material as a protective coating, offering a significantly improved lifespan. The goal is to improve mining efficiency, mitigate downtime, optimize performance, coat, productivity and support sustainable remanufacturing practices.