Understand the battle of wear resistance in high-impact, abrasive crusher environments—Manganese vs AR500.
Manganese Steel or AR500: What Should You Choose for Crushers?
Choosing the right wear plate for crusher applications can be the difference between frequent downtime and consistent production. Two industry favorites—Hadfield Manganese Steel (X120Mn12) and AR500 (Abrasion Resistant Steel)—are widely used. But they are not interchangeable.
Here’s a breakdown of how they perform in real-world mining, aggregate, cement, and recycling environments.
Key Properties Comparison: Manganese Steel vs AR500
| Property | Manganese Steel (X120Mn12 / ASTM A128) | AR500 Steel |
|---|---|---|
| Hardness | 200 BHN (as-delivered) → 500 BHN (after impact hardening) | 470–530 BHN fixed |
| Strength | High ductility and toughness | High hardness, lower elongation |
| Work-Hardening | Yes – gets harder on impact | No |
| Impact Resistance | Excellent | Moderate |
| Abrasion Resistance | Moderate (improves under load) | Excellent |
| Magnetic | Non-magnetic | Magnetic |
| Weldability | Requires special electrodes | Better weldability |
| Machinability | Difficult | Easier to cut/drill |
| Best For | High impact zones like jaws, mantles | Sliding abrasion zones like chutes |
Where Manganese Steel Wins
- Crusher Jaws & Mantles – Self-hardens with impact, ideal for primary crushing.
- High-impact zones – Shock-absorbing properties prevent cracking.
- Boulder-crushing or oversized aggregate zones – Handles repeated blows.
If your crusher operation includes frequent impact with boulders, Hadfield manganese steel is unbeatable.
Where AR500 Outperforms
- Hopper liners, chutes, buckets – Excellent resistance to sliding abrasion.
- Cyclones and screens – Handles fine particle abrasion better.
- Secondary flow zones – No need for impact work-hardening.
If your wear environment is sliding, grinding, or abrasive with minimal impact, AR500 will last longer than manganese.
Why You Should Never Use Manganese in Pure Abrasion Zones
According to JADCO, manganese fails in environments without enough impact. Since it starts soft (~200 BHN), it wears away before it can work-harden—resulting in premature failure.
In contrast, AR500 starts hard out-of-the-box and handles abrasive loads from day one.
Common Mistakes in Crusher Plate Selection
- ❌ Using manganese liners in chute zones (zero impact)
- ❌ Using AR500 in primary impact jaws (leads to cracking)
- ❌ Not considering work-hardening properties of manganese
- ❌ Overlooking abrasive particle flow when choosing AR500
Dual-Plate Crusher Designs: The Hybrid Advantage
Many OEMs now use a combination of Manganese + AR500:
- Jaws/Mantles → Manganese
- Chutes/Liners → AR500
- Hopper edges → AR400 (toughened version)
This hybrid approach maximizes both impact strength and abrasion resistance, reducing total maintenance costs.
Voice Search Optimized FAQs (AEO Friendly)
1. Is AR500 better than manganese for crushers?
Only in sliding abrasion zones. Manganese is better for high-impact zones like jaw crushers.
2. Can I replace crusher jaws with AR500 plates?
Not recommended. AR500 will crack under heavy impact. Use Hadfield manganese steel instead.
3. Why is manganese used in primary crushers?
Because it work-hardens with impact, becoming stronger during use, and absorbs shock without fracturing.
4. When should I use AR500 instead of manganese steel?
Use AR500 in chutes, buckets, hoppers, and sliding zones where abrasion is high but impact is low.
Which lasts longer: AR500 or manganese?
Depends on application. For impact, manganese lasts longer. For abrasion, AR500 performs better.
Summary Table: Application-Based Selection
| Application | Recommended Material |
|---|---|
| Jaw Crushers | Manganese Steel |
| Cone Crushers | Manganese Steel |
| Hopper Liners | AR500 |
| Chutes and Slides | AR500 |
| Crusher Mantles | Manganese Steel |
| Transfer Points | AR400/AR500 |