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You are here: Home / Archives for Abrasion

Abrasion

C1000 Coated Rebuilt Screw – Extrusion, Abrasive Wear

December 11, 2018 by proboscidian

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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Filed Under: Abrasion Tagged With: Extrusion

C9000 Millennium Carbide Screw and Barrel – Extrusion, Abrasive Wear

December 11, 2018 by proboscidian

The Problem:

Extreme Coatings was asked to contact an extrusion customer with a high wear process. This is a 6”, 32:1 screw with a barrier flight and mixer. The screw extrudes sheet of high load calcium carbonate (70%) filled polypropylene which is then formed into sound deadening panels. From 10 to 20% regrind is fed back into the process and most wear is concentrated in the feed section of the screw.

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Filed Under: Abrasion Tagged With: Extrusion

C9000 Millennium Carbide Feed Screw – Extrusion, Abrasive Wear

December 11, 2018 by proboscidian

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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Filed Under: Abrasion Tagged With: Extrusion

Polymer Degradation / Surface Build Up – Injection Molding, Abrasive Wear

December 11, 2018 by proboscidian

The Problem:

A large blow molder was experiencing high scrap rates processing TiO2 filled HDPE on a standard chrome plated feed screw. They wanted to reduce carbonized material that resulted from sticking, charring and eventual release into the product. Screws are pulled every four months to be cleaned (sooner if necessary) and then reinstalled into whichever machine is next in rotation. Various screw designs are used depending on the polymer being processed. They have over 100 machines at this site and a total of eight manufacturing locations.

Previous chrome plated OEM screws required surface repolishing at six months and again at nine months. TiO2 attack and frequent cleaning roughened the screw surface which lead to stripping and re-chrome plating at about ten months.

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Filed Under: Abrasion Tagged With: Injection Molding

C1000 Tungsten Carbide – Injection Molding, Abrasive Wear

December 11, 2018 by proboscidian

The Problem:

This process suffers an extreme wear rate. Fifty mm, CPM-9V screws last three to five months running a polyamide based material with up to 60% glass fiber fill. This is a metal replacement material used to make structural automotive Class A parts.

A combination of high glass fiber filler and large shot utilization shorten screw and barrel life. The facility has more than 50 machines operating around the clock and process conditions are monitored closely to determine when a wear condition exists. Loss of cushion leads to a tip assembly replacement. Increased recovery time means a worn screw and barrel and typical preventive maintenance consists of removing the old barrel and screw as one piece and depositing them whole in the dumpster. New screw, barrel and tip are then installed to reduce down time and keep producing.

Their 300 ton Van Dorn machines were using 90% of the available shot size which reduced polymer residence time and greatly accelerated system wear. The customer increased screws and barrels from 50 to 57 mm to increase shot size and improve residence time. They also decided to evaluate carbide encapsulation as the price of CPM-9V tool steel was high and larger screws required 30% more material to manufacture.

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Filed Under: Abrasion Tagged With: Injection Molding

C9000 Millennium Carbide – Injection Molding, Abrasion

December 11, 2018 by proboscidian

The Problem:

A major feed screw manufacturer asked Extreme Coatings to help solve a severe abrasion issue with a large injection molding customer. This is dedicated equipment processing an engineered nylon with 15% glass fiber and 20% glass bead filler. Previous CPM-9V screws experienced as much as .035” (0,87 mm) wear in two months or less. They process with a reverse temperature profile and recommended polymer residence times. The customer wanted to maintain screw design across all equipment so a specific screw design change was not contemplated for this process.

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Filed Under: Abrasion Tagged With: Injection Molding

C9000 Millennium Carbide – Ceramic Injection Molding, Abrasion

December 11, 2018 by proboscidian

The Problem:

This customer approached us at a trade show looking for help to solve a severe abrasion problem coupled with product contamination. The process is proprietary and details are confidential.

This is a Powder Injection Molding process and, as is common to this process, parts are sintered after molding to achieve final size and part density. Clarity of the finished part was extremely important and any contaminants in the process usually showed up as a darkening of the sintered part.

These are small parts being processed on small 30 ton machines. Past wear protection consisted of a surface hardening treatment to infuse an elemental material into the screw surface resulting in a hard layer. High temperatures were required to achieve this layer and post heat treat straightening was difficult. The result was a screw and barrel with a large initial clearance of about .009”, which accelerated wear and shortened component life. Hard surfaced screws lasted about 3 months and 300,000 shots until product contamination lead to too much scrap and the screw was replaced.

As this hard layer wears, the softer substrate is exposed, which accelerates wear. More importantly, wear increases the amount of contaminants in the finished product causing a loss of clarity. Scrap goes up.

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Filed Under: Abrasion Tagged With: Injection Molding

C1000 Encapsulation – Injection Molding, Abrasive Wear

December 11, 2018 by proboscidian

The Problem

A large custom compounder makes a thermally conductive material designed to dissipate heat quickly and effectively. This product is highly filled with a proprietary material that causes their customers severe abrasive wear. This has actually limited the product’s acceptance even though the resin is less expensive than other materials and very effective.

This compounder was approached by their customer asking for a solution to rapid wear. They in turn asked Extreme Coatings to contact this processor to offer help.

This customer makes parts for the home appliance market, in this case, washing machines. This thermally conductive material was specified by the manufacturer for an inlet flume that incorporated temperature sensors to control and mix incoming hot and cold water.

Standard molding equipment was used to process the first batch of parts. The Maintenance Manager commented that “the feed screw looked like a broom stick in one week running that stuff!” CPM-9V feed screws lasted 20,000 shots with .030” total OD wear in 1-1/2 months. These parts are batch produced in a campaign every four months throughout the year.

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Filed Under: Abrasion Tagged With: Injection Molding

Feed Screw Coatings – Injection Molding, Abrasive Wear

December 10, 2018 by dave

The Problem:

This customer makes consumer products for the Lawn and Garden industry. Economics of operation has lead to much of their production activity being moved to lower cost countries. This plant countered the trend by making better quality finished products (longer life) at a lower cost than the offshore site.

They process a 33% glass filled nylon material making structural engine housings. These parts require strength and heat resistance. This is a large part approximately 2-1/2 to 3 lbs shot size on an 80 mm 18:1 feed screw. Cycle times are about 1 minute which means polymer residence time is very short and with a nylon material this can contribute to more rapid wear.

Past 80 mm GP screws were hard faced with Colmonoy 56 and hard chrome plating. At six months of 24/7 operation these screws had as much as .030” of OD wear. Root wear and flight side erosion were also evident which made screw rebuilds uneconomical.

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Filed Under: Abrasion Tagged With: Injection Molding

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    • The Process
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      • Full Encapsulation of Feedscrews
      • Partial Encapsulation of Feedscrews
    • Chrome Plating Replacement
      • Feedscrews, Mixing Rotors, etc.
      • Mud Rotors and Downhole Tools
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      • Feedscrews
      • Parallel Twin Feedscrews
      • Co-Rotating Twin Feedscrews
      • Ultrasonic Welding Horns
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      • Mixer Bodies
      • Extrusion Dies, Die Plates, Sheet Dies
      • Granulator Knife Blades
      • High intensity Mixing Blades
      • Elbows For Pneumatic Conveying
      • Spin Dryer System
    • Oil & Gas Industry
      • Downhole Mud Rotors
      • Mandrels
    • Motorsports Industry
    • Marine Anti-Fouling
  • Technical Resources
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      • Tungsten/Chromium Carbide
      • NiBoride
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      • Abrasive Wear Test ASTM G65
      • Adhesive Wear Test ASTM G77
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