Microstructure‐dependent abrasive wear behavior of metallic alloys under tumbling abrasion

Grinding media consumption accounts for a significant portion of total operational expenses in mineral processing, reaching up to 45 %. This study examines the correlation between microstructure and abrasive wear resistance of metallic alloys under tumbling abrasion, with a focus on practical applications in mineral processing. The novelty lies in establishing systematic links between carbide morphology, matrix hardness, and wear mechanisms in environments of quartz sand and iron ore. Abrasive wear tests were conducted using the SSAB (Swedish Steel AB) tumbling abrasion method, which represents high‐stress wet grinding conditions involving ball–ball and ball–drum collisions, as also defined in previous laboratory ball mill investigations and in more recent analyses of abrasion classification in grinding media. The results show that high‐chromium cast irons exhibit the lowest wear rates (0.18 cm 3 /week), while low‐alloy steels experience up to five times greater volumetric loss (0.91 cm 3 /week). Scanning electron microscopy reveals micro‐grooving and matrix detachment in more complex alloys, whereas softer steels display significant corrosion‐assisted pitting and cracking. These findings provide practical guidelines for alloy design and the selection of grinding media, underscoring the importance of microstructural control in tailoring materials to specific abrasive environments.