In the crushing business, a composite hammer is only as good as its weakest link. Usually, that link is the interface between the hard insert and the steel base. If that bond fails, you face catastrophic delamination. At Broadcarbide, we don’t just hope the bond holds; we verify it. Using Cold Cast-in Technology, we create a junction that withstands the most brutal impact forces in the industry.
Section 1: The Microscope Doesn’t Lie
When we slice open one of our composite hammers to inspect the quality, the results are clear. The boundary between the cold-cast TM52 insert and the high-manganese steel base is distinct and sharp.
Zero Defects: We don’t see shrinkage holes or cold laps. The interface is compact and clean.
Seamless Integration: Industry researchers describe this as a “seamless” combination. The molten steel wraps perfectly around the insert, leaving no gaps for stress fractures to start.
Section 2: The 10-Micron Proof
We dug deeper using energy spectrum analysis to see exactly what happens at the molecular level.
The Transition Zone: Right at the center of the bond, we see high peaks of Titanium (from our insert) and Iron (from the steel).
Precision Bonding: Just 10µm away from that center line, the Titanium signal vanishes, leaving only Iron.
What This Means: It proves our interface layer is incredibly thin because the steel solidifies instantly against the cold block5. But don’t let the thinness fool you—the bonding strength is exceptionally high, ensuring the insert reinforces the base without popping out.
Section 3: Why We Don’t Need “Dog-Teeth”
You might hear competitors talk about needing a jagged, “dog-tooth” metallurgical bond for strength. In reality, forcing that kind of bond requires excessive heat, which can damage the carbide’s skeleton.
Our Cold Cast-in method creates a dense, mechanical and chemical lock. It protects the hard carbide phase while ensuring the insert stays locked in, even when the hammer is spinning at full RPM.
Final Thoughts
We don’t chase theoretical perfection; we chase operational reliability. Our Cold Cast-in interface is proven to hold.