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Extreme Coatings

Call: 888-367-2569

Plastics Industry Association Member

Engineered Surfaces to Extend Service Life and Performance

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      • Full Encapsulation of Feedscrews
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  • High Performance Formulas
    Extreme Layer of Protection
    HVOF Thermal Spray
  • Reduce Replacement Costs for Mud Rotors
    HVOF CPR delivers more abrasion and corrosion resistance than hard chrome plating (HCP) - even in high chloride environments
    Read More
    Oil and Gas Industry
  • Plastic Injection Molding
    Twin Feedscrews
    Our high percentage carbide layer can provide from two to four times more wear life depending on fill loading.
    Read More
  • Feedscrews
    Our coatings are perfect for injection molders and extruders when processing fiberglass, calcium carbonate, titanium dioxide and metals, ceramic or other highly abrasive fillers.
    Single Feedscrews
    Read More
  • Mixer-Extruders
    Continuous Mixing Rotors
    Our C1000 tungsten carbide has been used as chrome replacement in aggressive applications. C1000 doubles the working life of rotors compared to hard chrome plating.
    Read More
You are here: Home / Technical Resources / FAQs

FAQs

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Will a hard tungsten carbide coating wear my “soft” barrel?

This is a common concern among processors. We commissioned an ASTM G-77 test procedure to address this issue. In brief, tungsten carbide spinning against a bimetallic (FeB) liner shows no difference in liner wear than standard alloy materials such as Stellite and Colmonoy. Follow this link for more details (Adhesive Wear Test ASTM G77). A hard coated feedscrew contacting a less hard barrel liner is not a source of wear. In extrusion, system alignment, auxiliary die and barrel support, temperature profile, and proper screw design are much more critical to reducing wear.
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Will a coating ever come off the feedscrew?

It can happen. The carbide coating has a mechanical bond to the screw surface. If the screw surface moves or flexes, the bond can be weakened which may lead to a release of coating. What can cause this movement? Excess heat such as a torch or cleaning oven can expand the screw surface. A cold start can result from operating equipment before sufficient heat input (soak) to soften any remaining polymer in the system. Non-compressible tramp material will gouge the screw surface and remove coating at the contact point.
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What if I need to remove the coating to re-cut my screw?

Extreme Coatings has the capability to “strip” the coating from a worn feedscrew. This feature is especially beneficial for large, complex, expensive feedscrews. A screw will eventually wear through the coating at the outside diameter (OD). When that happens simply remove the screw and coordinate with your screw supplier to have Extreme Coatings strip and re-apply a fresh layer of tungsten carbide.
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My feedscrews last a long time, can a coating benefit me?

We believe that any injection molding feedscrew that is replaced or rebuilt at 24 months or less will benefit significantly from encapsulation with carbide. Extrusion feedscrew that are rebuilt or replaced within five years will likewise see great benefit from carbide. Obvious gains are longer screw life, however intangible benefits such as consistent quality, through-put, lower energy and maintenance costs, as well as higher capacity utilization offer cost savings and competitive advantage.
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I have a technical question about a coating, can I contact Extreme Coatings directly?

Absolutely. Our toll free number is 888-367-2569. Ask for John, Tom or Greg.
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How much wear is too much for a typical feedscrew?

This depends on many factors. SPI guidelines suggest .0015” (.04 mm) per inch of screw diameter starting clearance between screw and barrel. For a 50 mm screw this is .003” (.08 mm) clearance per side or .006” (.13 mm) overall. Depending on resin viscosity, output can be reduced 25% with a doubling of this beginning clearance (.012”, .25 mm). The effect screw wear has on production and part quality should be an important consideration. An extrusion system can be especially sensitive to adhesive wear of the feedscrew outside diameter.
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How much longer will my feedscrew last?

Our standard guarantee is double life. In an abrasive process like glass filled nylon, the ASTM G-65 test (Abrasive Wear Test ASTM G65) shows that carbide encapsulation will be three times better than the next best material. From experience we have learned that wear life can improve by three to five times compared to the feedscrew being replaced.
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How much extra time does it take to get my screw coated?

Our quoted lead time is ten business days. We average six to seven days. Depending on feedscrew diameter, we can meet a “rush” delivery if given prior notice.
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How much does it cost to encapsulate my feedscrew?

We provide the Extreme Coatings encapsulation service through your feedscrew manufacturer. Your screw supplier is our direct customer. We do not set the price that you will pay, but experience has shown that a carbide encapsulated feedscrew will cost about twice as much as a screw protected with hardfacing and chrome plate. Compared with tool steels, carbide encapsulation will cost about fifty to sixty percent more. Remember, in all cases, we guarantee at least double the life.
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Does Extreme Coatings make new feedscrews?

Extreme Coatings does not make new screws or rebuild worn feedscrews. We encapsulate screws to make them last longer. We work with your present feedscrew supplier to provide this service.
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Does Extreme Coatings have references? Who works with Extreme Coatings?

Extreme Coatings has a solid reputation as the premier supplier of carbide encapsulation of feedscrews to the plastics and rubber processing industries. Extreme Coatings is a service mark of Surface Engineering & Alloy Company, a wear resistance company with 30 years experience solving wear problems. Since 1997, we have carbide encapsulated over 5500 feedscrews worldwide with great success. We work with all feedscrew and equipment manufacturers. It is likely we have supplied our service through your present feedscrew source. We encourage you to ask about our reputation for quality and aftersales service with your supplier.
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Can I send my worn feedscrew to Extreme Coatings to be repaired?

Not directly. We supply this coating service through your present feedscrew supplier or original equipment manufacturer. A worn feedscrew should be sent to your screw supplier for any necessary repairs and then prepared for carbide encapsulation. Your supplier will send the coating-ready feedscrew to Extreme Coatings to complete the process.
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Can Extreme Coatings coat my mold/die/calibrator/widget?

This is also a common question. After we improve feedscrew life, processors find a downstream component, profile die, calibrator, non-return valve, or other part that wears “quickly”. We have tried to solve a lot of these issues with thermal spray coatings and have learned that some respond well, others not. For inside diameter surfaces we offer our NiBoride nickel boride material. Click here for more details. . For non-return valves – tip assemblies, we have developed the Cushion Master. This is a solid tungsten carbide check ring and rear seat that provides from six to eight times the life of standard tip assemblies. Click here for more details.
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Can Extreme Coatings apply this same material to my barrel?

We get asked this question a lot. The answer is no. Our process is line-of-sight and we cannot fit the spray apparatus inside a barrel. Spin cast barrel liners of tungsten carbide are available from all the major barrel suppliers.
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Extreme Coatings

2895 46th Ave N - St. Petersburg, FL 33714

ISO 9001 2015 Certifiedby WCS ISO 9001 2015 Certified by WCS ISO 9001:2015 Certified by WCS

888-367-2569

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  • Home
  • About Us
    • Shows and Events
    • News
  • Our Processes
    • High Velocity Thermal Spray
    • The Process
    • Encapsulation Protection
      • Full Encapsulation of Feedscrews
      • Partial Encapsulation of Feedscrews
    • Chrome Plating Replacement
      • Feedscrews, Mixing Rotors, etc.
      • Mud Rotors and Downhole Tools
  • Applications
    • Plastic & Rubber Industries
      • Feedscrews
      • Parallel Twin Feedscrews
      • Co-Rotating Twin Feedscrews
      • Ultrasonic Welding Horns
      • Cushion Master
      • Continuous Mixing Rotors
      • Mixer Bodies
      • Extrusion Dies, Die Plates, Sheet Dies
      • Granulator Knife Blades
    • Oil & Gas Industry
      • Downhole Mud Rotors
      • Mandrels
    • Motorsports Industry
    • Marine Anti-Fouling
  • Technical Resources
    • Coating Formulas
      • Tungsten/Chromium Carbide
      • NiBoride
      • Other
    • Test Results
      • Abrasive Wear Test ASTM G65
      • Adhesive Wear Test ASTM G77
    • Case Studies
    • FAQs
    • Company Literature
    • ROI
    • Videos
  • How to Buy
    • Our Distributors
    • Purchase Encouragement Program (PEP)
    • Warranty
  • Contact Us
    • Application Profile Form
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