SCREW & BARREL
METALLURGY & SERVICE LIFE
Mrunal Sanghvi
Regional Sales Manager
Nordson Xaloy Asia (Thailand) Ltd.
Topics of Discussion
Current Requirements
Screw & Barrel Wear
Types of Wear
Screw & Barrel Metallurgy
Wear Solution - Bimetallic Barrel & Screw
Screw & Barrel Service Life
Conclusion
Current Requirements
Demands of End Products of Extrusion &
Molding are getting more stringent, needs
To use Better, High Performance Polymer
To use Blends of various Polymers and Additives
Better Strength and other Mechanical Properties
Better Transparency, Gloss, Optical & Surface
Properties
Tighter Dimensional & Weight Control
Lower Price
Current Requirements
Extrusion, Injection Molding and Blow Molding
Machines requires to provide
Higher Output / Productivity
Flexibility to process various Polymers & Additives
Ability to process more & more fillers
Ability to process recycled polymers in many
applications
Lower Power Consumption
Lower Process Waste
Current Requirements
All these demands of End Products and
Machines Performance leads to Higher Abrasion
& Corrosion of Screw & Barrel
We see more and faster wear with Screw &
Barrel than what we used to see before 10 years
with many applications
Many Processors & OEMs are wondering how to
handle this problem
Barrel & Screw
Screw & Barrel - Wear
What happen in case of Wear?
When Screw & Barrel wears, the gap between them
increases which increase back flow of the melt
(Polymer) in side the Extruder / Molding Machine.
Rise of Melt Temperature and Residence Time
Reduction of Output / Plasticizing capacity
Screw & Barrel - Wear
Wear Sign in Extrusion are
Need to increase screw speed to achieve same
amount of output
Over all reduction in output (specific output
kg/hr/rpm)
Rise in Melt Temperature
Inferior Dispersion
Degraded particles or some time un-melted particles
Higher thickness / GSM variation / Weight variation
Higher Power Consumption
Screw & Barrel - Wear
Wear Sign in Injection Molding are
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Slippage of Screw
Longer Recovery Time
Longer Cycle Time
High Melt Temperature and Cooling Time
Inferior Dispersion
Degraded particles or some time un-melted particles
Surface defects like silver streaks, air voids, splay etc.
Screw & Barrel - Wear
Penalty of Wear
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Lower Output / Productivity
Poor Product Quality
Higher Wastage / Rejection
Higher Power Consumption
Higher Production Cost
Lower Contribution
Lower Profitability
Types of Wear
There are three different types of wears are
observed with Screw & Barrel
Adhesive Wear
Abrasive Wear
Corrosive Wear
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Types of Wear Adhesive Wear
Wear occur due to metal to metal contact of
Screw & Barrel while screw is rotating
Reasons of Adhesive Wear (Galling)
Cantilever mounting of the screw
Buckling of screw due to back pressure
Screw Design, Polymer used & Process Parameter
Screw & Barrel Straightness & Manufacturing
tolerances
Screw & Barrel Concentricity / Alignment
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Types of Wear Abrasive Wear
Wear occur through contact of Foreign or
Abrasive Particle of Resin with Screw & Barrel
Reasons of Abrasive Wear
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Buckling of screw due to back pressure
Screw Design & Process Parameter
Nature of Polymer (mLL is abrasive than LD)
Some additives are also very aggressive to metal
wear , e.g. CaCO3, TiO2, Silica, Glass Fibers,
Metal Particles etc.
Types of Wear Corrosive Wear
Wear occur through corrosion of Screw &
Barrel when it comes in contact with Polymer /
Additives / Gases
Reasons of Corrosive Wear
Mainly due to corrosive nature of Polymers & Additives
Screw Design & Process Parameter
Some polymers are corrosive in nature, e.g. Acid Copolymer
is corrosive than LDPE or CPVC corrosive than RPVC
Some additives are corrosive in nature, Halogen Free Flame
Retardants, Ink of Recycled Printed Films etc.
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Screw & Barrel Metallurgy
In general, any screw & barrel is bound to wear in any machine.
Amount of wear can be different. Selection of metallurgy is a
major tool under control for machine manufacturer.
Options of Screw & Barrel steel used in industry are
Screw
AISI4140/CP Very rare application
AISI4140/Flame Hardened/CP Very limited application, not in Asia
Nitriding Steel Most Commonly used Steel
Tool Steel Increasing usage, for dia. less than 50 mm
Bimetallic Screw Increasing usage, for dia. above 50 mm
Barrel
Nitriding Steel Most Commonly used Steel
Tool Steel Rarely used for small dia.
Bimetallic Barrel Getting standard with many applications
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Screw & Barrel Metallurgy
Nitriding Steel is most commonly used in India for
manufacturing of Screw & Barrel
Skin Hardening is done through either Gas Nitriding or
Ion Nitriding
Hardness can go high up to 70 HRc, normally finished
parts Hardness in the range of 60 68 HRc
Hard Skin depth in the range of 0.4 0.6 mm
Easy and economic process, serve many applications
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Screw & Barrel Metallurgy
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Screw & Barrel Metallurgy
However, many applications & economy of the
business demand to increase the service life of
Nitrided Screw & Barrel
The option is to use Bimetallic Barrel & Screw
Bimetallic Barrel & Screw can offers 3 to 7 times
higher abrasion resistance compare to Nitriding Steel
depending on grade of Bimetallic Parts.
Right metallurgy and manufacturing process of
Bimetallic Barrel & Screw decide the performance
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Wear Solution -Bimetallic Barrel
Two metals
High tensile
strength backing
steel
Anti-abrasive /
corrosive alloys
lining
Hard Face Layer
of average 1.5
mm Thickness
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Wear Solution -Bimetallic Barrel
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Various Grades
X-102
X-200
X-306
X-800 (Tungsten
Carbide)
Wear Solution -Bimetallic Barrel
X-102 : Iron base matrix, Ferrite Boride / Carbide,
58 62 HRs
X-200 : Iron base matrix, Chromium Boride / Carbide,
64 - 69 HRs
X-306 : Nickel base matrix, Chromium Boride,
48 56 HRs
X-800 : Nickel base matrix, Tungsten Carbide,
58 66 HRs
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Wear Solution -Bimetallic Barrel
Xaloy X800 VS Nitride
Steel
Relative Life on Weight Loss Basis
20
15
10
5
0
X800
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X102
Gas Nitride
Ion Nitride
Wear Solution Tool Steel Screw
Tool Steel Screw
D2Modified Through Hardened Tool Steel, Offers good
abrasion & good corrosion resistance, 58-62 HRc
NPR1 Through Hardened Tool Steel, Offers very high
abrasion & very high corrosion resistance, 58-62 HRc
N690 Through Hardened Stainless Steel, Offers good
abrasion & very high corrosion resistance, 52-56 HRc
Powder Metallurgical (PM) Tool Steel
CPM 9V - Through Hardened PM Tool Steel, Offers extremely
high abrasion & very high corrosion resistance, 52-55 HRc
CPM S90V - Through Hardened PM Tool Steel, Offers
extremely high abrasion & extremely high corrosion
resistance, 54-59 HRc
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Wear Solution -Bimetallic Screw
Bimetallic Screws has
two Metals
Anti Abrasive / Corrosive
Hard Facing Layer, Ave.
thickness of 1.5 mm
Base material
Root treatment
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Wear Solution -Bimetallic Screw
Hard Facing Layer - Cobalt
Base Stellite 6, Stellite 12,
Nickel Base - X-183, X-830
Root treatment, Chrome
Plating when AISI4140 or
AISI4340, Nitriding when
SACM645
Base Steel, AISI4140, 4340,
SACM645, Stainless Steel
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Wear Solution -Bimetallic Screw
Hard Facing Material
Stellite 6 Cobalt Base, 38-42 HRs, Galling a lot, Now least
preferred
Stellite 12 Cobalt Base, 44-48 HRs
X-183, Nickel Base, Chromium Boride, 46-52 HRc, Very
Good Abrasion and Corrosion Resistance
X-830, Nickel Base, Tungsten Carbide, 48-55 HRc, Extremely
High Abrasion and Corrosion Resistance
Root Treatment
Chrome Plating, 0.03 to 0.10 mm, 50 to 65 HRc
Nitriding, 0.3 to 0.5 mm, 65 to 68 HRc
Encapsulation and fusion of TC, 60 to 68 HRc
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SCREW WITH HVOF COATING
Screw with HVOF Coating
HVOF (High Velocity Oxygen Fuel) process can be used to
coat Screw Flight OD & total Encapsulation of Screw
It is coating process and not the hard facing process
Tungsten Carbide, 0.125 mm to 0.250 mm Thickness
Problem of Adhesion, Coating is brittle in nature
Coating is prone to crack and nicked under torsional force,
which generate rapid deterioration of the base steel which
also encourage faster Shelling Off of the coating
Fusion process must be used to improve bonding (i.e.
fusion) of coating with base material
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Screw & Barrel Service Life
There are many parameters which affect the
over all Wear process of Screw & Barrel, these
are
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Diameter & Length
Design of Screw & Barrel
Metallurgy of Screw & Barrel
Manufacturing of Screw & Barrel
Alignment of Screw & Barrel
Screw & Barrel Service Life
Polymer & Additives
Process Parameters
Speed
Temperature
Pressure
Maintenance of screw & Barrel
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Screw & Barrel Service Life
Screw & Barrel Service Life
Nobody can predict exact service life of Screw &
Barrel
There is no science to predict the service life of Screw
& Barrel
One can predict screw & barrel life only when they
were experienced before. Would say experience for
same Size, Design, Metallurgy for very similar
Application, Polymers, Process Parameters and
Operating, Maintaining people
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Conclusion
Any Screw & Barrel will wear, rate of wear can be
different
Nobody can predict exact life of Screw & Barrel
Screw & Barrel wear reduce productivity, quality &
profitability
When life of Nitrided Screw & Barrel is not enough,
Bimetallic is the only solution
In many applications where there is high wear, using
Nitrided Screw & Barrel offers more loss (hidden loss)
Bimetallic Barrel & Screw may demand higher capital
investment but offers better productivity, quality and
Profitability
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THANK YOU
Mrunal Sanghvi
[email protected]
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