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Extrusion

C1000 Coated Rebuilt Screw – Extrusion, Abrasive Wear

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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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Process Stability with C1000 Tungsten Carbide – Extrusion, Adhesive Wear

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The Problem:

A blown film producer of custom and engineered blends sees loss of film properties and surface appearance from a small amount of wear. A particular process makes foamed MW PE and wear of the screw mixer leads to temperature differences, poor mixing and surging at the die interface. As these are high performance liners, consistency of output and process stability are extremely important for high quality products.

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C1000 With A Mirror Polish Finish for Process Consistency – Extrusion, Adhesive Wear

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The Problem:

This customer extrudes foamed PE sheet which is used to seal consumer products. Sheet thickness ranges from 4 to 40 mils and the material is used in applications such as food bottling or pill bottles. Wear is a critical factor as too much heat input due to screw wear causes poor control of foamed product sizing. In a foaming operation, process stability is very important. A reduction in output as a result of wear is not an issue compared to the poor quality product that results from an increase in melt temperature.

This is a 4-1/2”, 24:1 screw with a barrier flight and double mixers. The screw has a weld inlay of Colmonoy 56 on flight lands and hard chrome plating. At .010” of OD wear, process stability is affected and at .020” wear a screw is removed and rebuilt. The average screw life is about 12 to 14 months. The foamed PE also contains 4-5% titanium dioxide as a whitening agent.

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C9000 Millennium Carbide Screw and Barrel – Extrusion, Abrasive Wear

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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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C9000 Millennium Carbide Feed Screw – Extrusion, Abrasive Wear

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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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