Maximizing Performance with CastoChrome® Blow Bars

VAUDREUIL-DORION, Quebec - EntSun -- Blow bars are the primary wear component in horizontal shaft impactors (HSIs), delivering the crushing force required to break down feed material. Their performance has a direct impact on plant efficiency, product consistency, and maintenance planning. Yet many operations still rely on standard OEM blow bars that lack advanced wear-resistant technologies—particularly ceramic reinforcement—leading to premature wear and unplanned downtime. To overcome these limitations, Castolin Eutectic introduces ZeraCore, a next-generation ceramic reinforcement technology designed to significantly improve both wear resistance and toughness in high-impact crushing environments.

Understanding Blow Bar Wear
Blow bars endure a combination of high-velocity impact and abrasive wear. The wear profile is typically non-uniform, with the leading edge and feed-facing surfaces experiencing the highest degradation. Once the protective layer—often a ceramic insert—is worn through, the underlying metal erodes rapidly, accelerating failure.

Standard OEM blow bars often lack ceramic inserts altogether, relying solely on martensitic or high-chrome alloys. While these materials offer some resistance, they are no match for the wear demands of high-silica aggregates or recycled concrete.

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In contrast, ceramic-encapsulated blow bars, especially those with extended insert depths, offer a critical advantage. They deliver a more gradual wear curve, prolonged service intervals, and ultimately, improved performance consistency. CastoChrome blow bars with ZeraCore technology push these advantages even further.

Material Selection for Demanding Applications

Choosing the right blow bar material depends on the crushing environment:
• Martensitic Steel offers good toughness and moderate wear resistance, making it suitable for mixed feed with occasional tramp metal.
• High Chrome Iron provides excellent abrasion resistance but is more brittle under high impact, making it best for consistent, non-reinforced feed.
• Ceramic Composites combine the toughness of metal with the wear resistance of Zirconia Toughened Alumina (ZTA) ceramics. ZeraCore, our proprietary ZTA technology, offers the highest standard for high-wear, high-impact applications.

ZeraCore technology uses Zirconia Toughened Alumina (ZTA) ceramics, a significant upgrade over conventional alumina. ZTA offers higher fracture toughness, improved flexural strength, and better resistance to thermal shock. This combination allows the ceramic to absorb impact while resisting abrasion, dramatically extending blow bar service life.

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Proven Performance Gains
In a real-world recycling application, CastoChrome® blow bars equipped with ZeraCore technology helped triple crusher throughput when processing asphalt and concrete. Read the full case study here: https://www.castolin.com/en-CA/news/blow-bars

Where Material Science Meets Engineering
Blow bars are no longer simple consumables. They are precision-engineered components where material science, mechanical design, and advanced ceramics work together to improve reliability and productivity. With ZTA ceramics integrated through a proprietary design, ZeraCore technology delivers longer wear life, reduced maintenance, increased uptime, and a stronger return on investment for demanding crushing operations.

www.eutectic.ca