Tutorial Presentation

Adam Dreiblatt
Director, Process Technology

Diagnosis and Analysis of

Screw and Barrel Wear in
Twin-Screw Compounding
Extruders
 Presentation Outline
How and why extruders wear
– Wear mechanisms
Where extruders wear
– Process implications
Minimizing extruder wear
– Solutions for abrasive and adhesive wear
 Extruder Wear Mechanisms
Abrasive Wear

Corrosive Wear

Adhesive Wear
 Analyzing extruder wear
Abrasive Wear
Erosion of metal surfaces due to harder materials
(i.e. TiO2) rubbing against softer materials
 Analyzing extruder wear
Abrasive Wear
Localized to regions experiencing high mechanical
stresses
• Melting and mixing sections where abrasive
materials are present
• Conveying sections developing pressure
• Formulation-specific problem

Smooth, rounded edges; polished surfaces

 Analyzing Wear
Identifying abrasive wear
Abrasive wear is localized – identify where is the wear

Feeding
Melting
Mixing
Venting
Pressurization
 Where is the wear ?

Feed Zone

Feeding abrasive fillers into the main feed port – TiO2, CaCO3, talc, etc…
provides great dispersion at the expense of component lifetime
 Where is the wear ?

Feed Zone

As the flights of conveying elements are worn, conveying efficiency is

reduced. As wear progresses, feed-limitation can be observed (i.e.
backup into main feed port)
 Where is the wear ?

Feed Zone

Screw speed can be increased to compensate for reduced conveying

efficiency – for a while. Note that rate of wear of conveying elements is
accelerated with higher screw speed.
Where is the wear ?
 Where is the wear ?

Melting Zone

As the tips of kneading elements are worn, melting and mixing efficiency
are reduced. As wear progresses, melting of resin(s) and mixing of
additive(s) moves to downstream kneading elements.
 Where is the wear ?

Melting Zone

As wear progresses, deterioration of physical properties results from

decreased melting and mixing. Unmelted resin appears at side feeder,
downstream mixing of fillers is affected (venting problem at side feeder).
 Where is the wear ?

Melting Zone

Screw speed can be increased to compensate for reduced efficiency of

kneading elements – for a while. Note that rate of wear of kneading
elements is accelerated with higher screw speed.
As first
kneading
elements wear,
melting is
delayed – note
mixing cannot
start until
melting is
completed !
Wear in
melting section
can result in
unmelted resin
at side feeder –
this is usually
mis-diagnosed
as wear in
downstream
mixing section!
Note that
mixing does
not begin until
melting is
completed –
mixing time
decreases with
wear
 Where is the wear ?

Downstream
Side Feeder

Similar to wear of conveying elements prior to the melting section – conveying

efficiency also deteriorates as the downstream conveying elements wear and
is observed as a feeding limit at the side feeder (backup).
 Where is the wear ?

Downstream
Side Feeder

Screw speed can be increased to compensate for reduced conveying

and/or mixing efficiency – for a while. Note that rate of wear of conveying
and kneading elements is accelerated with higher screw speed.
 Where is the wear ?

Downstream
Mixing Zone

Feeding abrasive fillers downstream minimizes wear (compared to

feeding in main feed port); first kneading element(s) exposed to filler
experiences highest mechanical stress.
 Where is the wear ?

Downstream
Mixing Zone

Similar to wear of kneading elements in the melting section – mixing

deteriorates as the kneading elements wear and is observed as
decreased physical properties. Filler appears in vacuum vent or on
screens.
Minimizing Abrasive Wear
 Where is the wear ?

Vacuum Zone

If clearances are enlarged (from abrasive wear) within the restriction

element used to create a melt seal for vacuum, sustainable vacuum level
is reduced.
 Where is the wear ?

Vacuum Zone

Diagnosing a worn melt seal is easy – polymer is pulled from the vacuum
port only under vacuum; at atmospheric pressure, polymer remains
within the extruder screws.
 Where is the wear ?

Vacuum Zone

Screw speed can be decreased to compensate for worn restriction

elements to increase pressure drop – for a while. Note that melting and
mixing are decreased at reduced screw speed.
 Where is the wear ?

Pumping Zone

As the flights of conveying elements are worn in the pumping section,

conveying efficiency is reduced and the backup length required to develop
pressure increases to upstream (i.e. unworn) conveying elements.
 Where is the wear ?

Pumping Zone

Screw speed can be increased to compensate for reduced pumping

efficiency – for a while. Note that rate of wear of conveying elements is
accelerated with higher screw speed.
Where is the wear ?

With enlarged
clearances in
pumping
section, melt
backs-up
further into
last barrel
Where is the wear ?

As wear
progresses in
pumping
section, melt
eventually
backs-up into
vacuum vent
Where is the wear ?

With enlarged
clearances in
pumping
section, melt
temperature
increases from
increased
leakage flow
Where is the wear ?

With increased
leakage flow,
melt residence
time increases
(increased
backup length)
 Extruder Wear Mechanisms
Abrasive Wear

Corrosive Wear

Adhesive Wear
 Analyzing extruder wear
Corrosive Wear
Erosion of metal surfaces due to chemical attack
 Analyzing extruder wear
Corrosive Wear
Localized to regions experiencing chemical interaction
between raw materials and metal surface(s)
• Addition of corrosive materials prior to mixing
• Reaction by-product(s) evolving from
interaction between materials
• Formulation-specific problem

Rough, pitted surfaces

Corrosive Wear
Corrosive Wear
Corrosive Wear
 Extruder Wear Mechanisms
Abrasive Wear

Corrosive Wear

Adhesive Wear
 Analyzing extruder wear
Adhesive Wear
Rubbing of metal surfaces against each other
 Analyzing extruder wear
Adhesive Wear
Localized to regions experiencing abnormal
mechanical stresses
• Inadequate screw support/centering
• Shaft deflection
• Incorrect screw assembly

Can also be seen across the entire length of the

extruder where chronic mechanical problems exist
(i.e. gearbox timing, incorrect screw assembly, etc.)
 Diagnosing Adhesive Wear
Causes of Adhesive Wear
Adhesive wear WILL result when ALL of the following
are not provided:

• Centering and support of shafts

• Proper timing and assembly of elements
• Proper coupling of shafts to gearbox
• Proper barrel alignment
• Lubricating film between screws/barrel
 Diagnosing Adhesive Wear
Extent of Adhesive Wear
Some causes of adhesive wear produce symptoms
that are localized to specific regions of the extruder

Other causes of adhesive wear produce symptoms

that can be seen across the entire length of the
extruder
 Diagnosing Adhesive Wear
Evidence of Adhesive Wear
Some causes of adhesive wear produce forces
resulting in screws contacting the barrel surface
 Diagnosing Adhesive Wear
Evidence of Adhesive Wear
Other causes of adhesive wear produce forces that
result in screw-screw contact
 Diagnosing Adhesive Wear
Causes of Adhesive Wear
Adhesive wear WILL result when ALL of the following are
not provided:

• Centering and support of shafts

• Proper timing and assembly of elements
• Proper coupling of shafts to gearbox
• Proper barrel alignment
• Lubricating film between screws/barrel
Diagnosing Adhesive Wear
The viscous
material within
intermeshing, co-
rotating twin-screw
extruders acts as a
dynamic bearing,
providing support
and centering of
the screw shafts
within the barrel –
these “bearings”
are located where
the screws are
filled
The filled sections of the extruder are created by the screw design – so the
screw design provides support and centering of the screws within the barrel
Screw designs that do not provide filled sections within the extruder allow
screws to “move around” within and “rub” against the barrel surface
Screw designs that do provide filled sections, but not enough to support or
center the shafts also contribute to adhesive wear (usually on large diameter
and/or long L/D machines).
Adhesive wear from lack of support gets worse with low viscosity and/or high
screw speed and/or high discharge pressure
 Diagnosing Adhesive Wear

Without adequate centering of the screw shafts, high discharge pressure can
cause deflection (bowing) of the screw shafts – this condition produces
adhesive wear on the outer screw flights over an extended L/D
A
Flow Normal Screw Profile

Smoothed surface
on pushing side of
B flight
Flow Abrasive Wear

“Mushroom” or
C “anvil” shape of
Flow Adhesive Wear flights that rub on
barrel wall – on
both pushing and
trailing edges –
very sharp edges
Analyzing Adhesive Wear
 Diagnosing Adhesive Wear
Causes of Adhesive Wear
Adhesive wear WILL result when ALL of the following are
not provided:

• Centering and support of shafts

• Proper timing and assembly of elements
• Proper coupling of shafts to gearbox
• Proper barrel alignment
• Lubricating film between screws/barrel
 Diagnosing Adhesive Wear

Correct installation of screw elements on shafts and proper timing are

required to maintain constant clearances – problems occur when
spacers are omitted (e.g. ZME elements, offset kneading blocks, etc.)
Diagnosing Adhesive Wear
Evidence of improper
timing – when the
leading edge of one
screw contacts the
trailing edge of the
adjacent screw,
sometimes referred to
as “chatter marks”
 Diagnosing Adhesive Wear

If elements are not seated properly (gap between

elements, e.g. from contamination) – then elements
can move axially on shaft. Signs of adhesive wear
are evident as improper timing, damage on
leading/trailing edges of conveying screw flights.
Twisted screw shaft(s) produce the same effect as
improper timing – evidence of adhesive wear begins
where the shaft is twisted and continues to the end
of the screws.
 Diagnosing Adhesive Wear

While a rare occurrence, adhesive wear can also

result from incorrect timing/orientation from the
gearbox output shafts (shafts off by one spline) – in
this case, the “chatter marks” are visible along the
entire screw length (this machine would most likely
also produce excessive vibration while operating).
 Diagnosing Adhesive Wear
Causes of Adhesive Wear
Adhesive wear WILL result when ALL of the following are
not provided:

• Centering and support of shafts

• Proper timing and assembly of elements
• Proper coupling of shafts to gearbox
• Proper barrel alignment
• Lubricating film between screws/barrel
 Diagnosing Adhesive Wear

If one shaft does not seat completely into couplings – the other shaft
will also not seat properly.
This condition allows axial displacement of the shafts relative to each
other.
Adhesive wear (“chatter marks”) are observed throughout the entire
machine, appears as improper timing.
 Diagnosing Adhesive Wear

When inserting assembled screws into barrel, material within the

barrel (polymer residue, pellets, etc.) can be pushed back behind the
feed opening and prevent shafts from seating properly into the
couplings.
Incorrect assembly of split rings in coupling assembly also creates a
condition where one shaft can move axially.
Diagnosing Adhesive Wear
 Diagnosing Adhesive Wear
Causes of Adhesive Wear
Adhesive wear WILL result when ALL of the following are
not provided:

• Centering and support of shafts

• Proper timing and assembly of elements
• Proper coupling of shafts to gearbox
• Proper barrel alignment
• Lubricating film between screws/barrel
No adhesive wear Distinct separation
observed here (barrel where barrels meet
alignment OK)

Adhesive wear
from improper
barrel alignment
 Diagnosing Adhesive Wear
Causes of Adhesive Wear
Adhesive wear WILL result when ALL of the following are
not provided:

• Centering and support of shafts

• Proper timing and assembly of elements
• Proper coupling of shafts to gearbox
• Proper barrel alignment
• Lubricating film between screws/barrel
Analyzing Adhesive Wear
 Analyzing Wear
Identify your wear type
Note that chronic adhesive wear requires a change
in screw design to correct – and is NOT normal

Corrosive wear requires a metallurgical solution specific

to the chemistry involved

Abrasive wear is the most common type of wear in

compounding applications
 Minimizing Abrasive Wear
How much wear is OK?
The answer is not straightforward – depends on product
sensitivity with respect to dispersion; some materials
cannot be produced when even small amounts of wear
are observed, while other materials can be produced with
severe wear on screws and barrels…

You need to wear down the machine until you produce

‘bad’ material – at this point, you can measure dimensions
and understand your own threshold value for replacement
of components.
 Minimizing Abrasive Wear
Identify an appropriate metallurgical solution
Presentation describes wear of screw components –
barrel wear always accompanies screw wear, usually
at a slower rate

Reducing wear rate implies identifying suitable chemistry

for materials of construction and fabrication method

• Hot Isostatic Pressing (HIP)

• Powder Metallurgy (PM)
• Barrel liner, element crest welding, etc…
Minimizing Abrasive Wear
Minimizing Abrasive Wear
 Eliminating Adhesive Wear
Chronic adhesive wear
If screw design does not provide adequate support,
changing metallurgy is not a solution – the screw
design must be changed !

Gearbox timing, barrel misalignment, bent/twisted

screw shafts all produce chronic adhesive wear and are
caused by mechanical deficiencies – that must be
corrected !
 Eliminating Adhesive Wear
Chronic adhesive wear
If material does not provide adequate lubrication
between screws/barrel (e.g. in feed zone) – there are
metallurgical solutions to improve compatibility and
reduce ‘galling’

Selection of compatible metallurgy between screws and

barrels is critical to avoid adhesive wear in situations
where it would not normally exist (i.e. where materials
are incompatible – adhesive wear can develop during
clean-out, for example)
 Eliminating Adhesive Wear
One-time events
Adhesive wear observed after improper screw or
coupling assembly – is caused by “human error” and
requires proper training to avoid the same problem
from occurring again.
 Eliminating Adhesive Wear
Adhesive wear is NOT a normal condition
You should expect to replace extruder components
from abrasive or corrosive wear, this is the cost to
produce your material – like replacement of brakes,
tires, etc. on your car.

If there are metal particles in the engine oil in your car –

it is a sign that you have a serious (usually expensive)
problem – but you need to check the oil to know that
you have a problem. If you don’t bother to look – you
will find out when your engine fails…
Questions?

Thank You !