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Engineered Surfaces to Extend Service Life and Performance

Case Studies

C9000 Millennium Carbide Feed Screw - Extrusion, Abrasive Wear

The Problem

A manufacturer of extrusion equipment approached Extreme Coatings for help to solve a high wear issue with one of its customers. This proprietary process coats paper with a thin, uniform film of highly filled (iron ferrite) polymer. This film is later magnetized to create a printable paper with a magnetic backing.

Line speed is critical to quality film deposition and this dictates when a screw and barrel system is out of tolerance. When an uneconomic rate results the feed screw is removed and rebuilt. A 2-1/2” extrusion screw with C83 hard facing and chrome plating lasts about 70 days in operation. Total production at this point is about 150,000 Kg of material processed.

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C1000 Coated Rebuilt Screw - Extrusion, Abrasive Wear

The Problem

This extrusion customer produces friction material for use in automatic braking assemblies for consumer products such as washing machines and lawn mowers. This is basic profile extrusion of a proprietary heavily filled mineral/fiber material. The equipment is a Bonnot extruder with a 4” interrupted-flight screw designed to process high load materials.

Standard protection for the feed screw has been complete weld encapsulation of Colmonoy 56, nickel-based hard facing. Typical batch size is about 360 lbs. and after 150 batches (3 to 4 months production) the C56 protection has severe erosion. Flight outside diameter is also reduced and output rate becomes uneconomical and the screw is removed and rebuilt.

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