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Wear Resistant Extruder Screw: Regeneration of Screws

Research Proposal · September 2011

DOI: 10.13140/RG.2.1.1095.3207

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 Mansoura University
Faculty of Engineering
Production Engineering & Mechanical Design

Pre-masters

Wear Resistant Extruder Screw

(Regeneration of Screws)

Prepared by:
Basma Mohamad El-Tlhawy

Supervisor:
Prof. Dr. Eng. Ahmed M.M. El-Bahloul

2010-2011

1
 Mansoura University
Faculty of Engineering
Production Engineering & Mechanical Design

Pre-masters

Wear Resistant Extruder Screw

(Regeneration of Screws)

Prepared by:
Basma Mohamad El-Tlhawy

Supervisor:
Prof. Dr. Eng. Ahmed M.M. El-Bahloul

2010-2011

2
 PREFACE
Worldwide, extrusion lines successfully process more plastics into products than other
processes. This study provides a technical maintenance of extruder screw of plastic
extrusion lines. The aim is to repair worn screws with economical means. Contents aim at
making a helpful tool available to regenerate them practically.

The first chapter highlights the fundamental of extrusion process and its types, as well as
the most famous extrusion materials. Second chapter deals with the extruder screw, its main
types and design. Third chapter deals with the regeneration techniques. These techniques
make up the maintenance plan that the worn extruder screws need. In all these chapters, the
presentation is utilitarian; that is, it is limited to what is necessary to this study.

The final chapter involves the case study, as well as the previous inventions in this field.

I consider it a pleasure to thank all those involved for their cooperation in the preparation of
this study.

First all my thanks to Allah that without his help this study would not exist.

Special thanks must go to Prof. Dr. Eng. Ahmed M.M. El-Bahloul for his help, advice, and
support.

Thanks to SHOUMAN Company for Plastic Processing Equipments for their help.

My thanks go also to my family and my friends for all their patience and care.

Sincerely

Basma El-Tlhawy

September, 2011

3
 CONTENTS

PREFACE

CHAPTER ONE 1
FUNDAMENTAL OF EXTRUSION PROCESS
1.1 Introduction 2
1.2 Extrusion Process 2
1.3 Typical Extrusion Materials 3
1.4 Types 4
1.4.1 Blown Film Extrusion 4
1.4.2 Co-extrusion 5
1.4.3 Sheet/ Film Extrusion 6
1.4.4 Tubing Extrusion 6
1.4.5 Extrusion Coating 7
1.4.6 Compound Extrusions 7

CHAPTER TWO 8
EXTRUDER SCREW
2.1 Introduction 9
2.2 Basic extruder types 9
2.3 Functions of an extruder screw 9
2.4 Advantages of screw 10
2.5 Screw Design 10
2.5.1 L/D Ratio 11
2.5.2 Screw profile 11
2.5.3 Compression Ratio 12
2.5.4 Channel Depths 12
2.5.5 Helix Angle 13
2.6 Extruder Screw Materials 13
2.7Extruder Barrel 13

CHAPTER THREE 15
REGENERATION TECHNIQUES
3.1 Introduction 16
3.2 Diffusion Coating 16
3.3 Thermal spraying 16
3.4 Surfacing 18

CHAPTER FOUR 19
PREVIOUS INVENSIONS AND CASE STUDY
4.1 Previous Inventions 20
4.2 Case Study 21

CONCLUSION 24

4
 REFERENCES 26
LIST OF FIGURES
CHAPTER ONE 1
FUNDAMENTAL OF EXTRUSION PROCESS
Figure 1.1 Blown Film Extrusion Process 2
Figure 1.2 Plastic extruder 3
Figure 1.3 Blown film line (Photo: Reifenhauser, Troisdorf, Germany) 4
Figure 1.4 Extrusion unit of co-extrusion blown film line (Photo: 5
Barmag, Remscheid, West Germany)
Figure 1.5 Plastic thermoforming 6
Figure 1.6 A tubing extrusion line (Harrel, inc.) 7

CHAPTER TWO 8
EXTRUDER SCREW
Figure 2.1 High performance blown film extruder with die (Photo: 9
Windmoller and Holscher, Lengerich, Germany)
Figure 2.2 Geometry of extruder screw 10
Figure 2.3 A simple plastic extrusion screw 11
Figure 2.4 Schematic of vented extruder 12
Figure 2.5 Extruder Barrel 14

CHAPTER THREE 15
REGENERATION TECHNIQUES
Figure 3.1 Thermal spraying processes 17
Figure 3.2 Surfacing processes 18

CHAPTER FOUR 19
PREVIOUS INVENSIONS AND CASE STUDY
Figure 4.1 Worn Screws 22
Figure 4.2 Regeneration Process: Welding of flights 22

LIST OF TABLES
CHAPTER FOUR 19
PREVIOUS INVENSIONS AND CASE STUDY
Material comparison table 23

5
 CHAPTER ONE
FUNDAMENTAL OF EXTRUSION PROCESS

6
 CHAPTER ONE

FUNDAMENTAL OF EXTRUSION PROCESS

1.1 Introduction

Extrusion is any process in which a material is forced through a shaped orifice, with the
material solidifying immediately to produce a continuous length of constant cross section.
In plastic extrusion, thermoplastics are softened by heating prior to extrusion and, for the
shape to be held; the thermoplastics must be quickly chilled and, usually, supported while
cooling.

1.2 Extrusion Process

In most extrusion operations, the raw plastic material arrives as powders or pellets at room
temperature, and is gravity fed from a top mounted hopper into the barrel of the extruder, as
shown in Figure 1.1. The extrusion process must melt the plastic and homogenize it before
it enters the die. Therefore, heating and melting the feedstock, converting it from a cold
solid to a hot viscous liquid.

Figure 1.1 Blown Film Extrusion Process

The material enters through the feed throat (an opening near the rear of the barrel) and
comes into contact with the screw. The rotating screw forces the plastic beads forward into
the barrel which is heated to the desired melt temperature of the molten plastic (which can
range from 200 °C to 275 °C depending on the polymer). In most processes, a heating
profile is set for the barrel in which three or more independent controlled heater zones
gradually increase the temperature of the barrel from the rear (where the plastic enters) to
the front. This allows the raw plastic to melt gradually as they are pushed through the barrel

7
and lowers the risk of overheating which may cause degradation in the polymer, as shown
in Figure 1.2.

Figure 1.2 Plastic extruder

At the front of the barrel, the molten plastic leaves the screw and travels through a screen
pack to remove any contaminants in the melt. The screens are reinforced by a breaker plate
(a thick metal puck with many holes drilled through it) since the pressure at this point can
exceed 34 MPa. The screen breaker plate assembly also serves to create back pressure in
the barrel. Back pressure is required for uniform melting and proper mixing of the polymer.

After passing through the breaker plate molten plastic enters the die. The die is what gives
the final product its profile and must be designed so that the molten plastic evenly flows
from a cylindrical profile, to the product's profile shape. Uneven flow at this stage would
produce a product with unwanted stresses at certain points in the profile. These stresses can
cause warping upon cooling. Almost any shape imaginable can be created so long as it is a
continuous profile. The product must then be cooled and this is usually achieved by pulling
the extrudate through a water bath or by using external air cooling. Once the product has
cooled, it can be spooled, or cut into lengths for later use.

1.3 Typical Extrusion Materials

Typical plastic materials that are used in extrusion include but are not limited to:

 Polyethylene (PE)
 Polypropylene (PP)
 Acetal
 Acrylic
 Nylon (PA polyamides)
 Polystyrene (PS)
 Polyvinyl chloride
 Acrylonitrile butadiene styrene (ABS)
 Polycarbonate

8
1.4 Types

1.4.1 Blown Film Extrusion

This process is the same as a regular extrusion process up until the die. The die is an
upright cylinder with a circular opening similar to a pipe die. The diameter can be a few
centimeters to more than three meters across. The molten plastic is pulled upwards from the
die by a pair of nip rolls high above the die. Changing the speed of these nip rollers will
change the gauge (wall thickness) of the film. Around the die sits an air ring. The air ring
cools the film as it travels upwards. In the centre of the die is an air outlet from which
compressed air can be forced into the centre of the extruded circular profile, creating a
bubble. This expands the extruded circular cross section by some ratio (a multiple of the die
diameter). This ratio, called the blow up ratio (BUR) can be just a few percent to more than
200 percent of the original diameter. The nip rolls flatten the bubble into a double layer of
film whose width (lay flat) is equal to 0.5 the circumference of the bubble. This film can
then be spooled or printed on, cut into shapes, and heat sealed into bags or other items.
Figure 1.3 shows a blown film line.

Figure 1.3 Blown film line (Photo: Reifenhauser, Troisdorf, Germany)

9
1.4.2 Co-extrusion

Co-extrusion is the extrusion of multiple layers of material simultaneously. This type of

extrusion utilizes two or more extruders to melt and deliver a steady volumetric throughput
of different viscous plastics to a single extrusion head (die) which will extrude the materials
in the desired form. This technology is used on any of the processes such as blown film,
tubing, and sheet. The layer thicknesses are controlled by the relative speeds and sizes of
the individual extruders delivering the materials. Figure 1.4 shows an extrusion unit of co-
extrusion blown film line.

There are a variety of reasons a manufacturer may choose co-extrusion over single layer
extrusion. Often co-extrusion is used to apply one or more layers on top of a base material
to obtain specific properties such as UV-absorption, soft touch, matte surface, or energy
reflection, where it is needed on the surface.

One example is in the vinyl fencing industry, where co-extrusion is used to tailor the layers
based on whether they are exposed to the weather or not. Usually a thin layer of compound
that contains expensive weather resistant additives are extruded on the outside while the
inside has an additive package that is more suited for impact resistance and structural
performance.

Figure 1.4 Extrusion unit of co-extrusion blown film line (Photo: Barmag, Remscheid, West
Germany)
10
1.4.3 Sheet/ Film Extrusion

For products such as plastic sheet or film, the cooling is achieved by pulling through a set
of cooling rolls.

A common post-extrusion process for plastic sheet stock is thermoforming, where the sheet
is heated until soft plastic, and formed via a mold into a new shape. When vacuum is used,
this is often described as vacuum forming. As shown in Figure 1.5, thermoforming can go
from line bended pieces (e.g. displays) to complex shapes (computer housings), which
often look like they have been injection molded.

Figure 1.5 Plastic thermoforming

1.4.4 Tubing Extrusion

Extruded tubing process, such as drinking straws and medical tubing, is manufactured the
same as a regular extrusion process up until the die. Hollow sections are usually extruded
by placing a pin or mandrel inside of the die and in most cases positive pressure is applied
to the internal cavities through the pin. Figure 1.6 shows a tubing extrusion line.

Tubing with multiple lumens (holes) must be made for specialty applications. For these
applications, the tooling is made by placing more than one pin in the center of the die, to
produce the number of lumens necessary. In most cases, these pins are supplied with air
pressure from different sources. In this way, the individual lumen sizes can be adjusted by
adjusting the pressure to the individual pins.

11
 Figure 1.6 A tubing extrusion line (Harrel, inc.)

1.4.5 Extrusion Coating

Extrusion coating is using a blown or cast film process to coat an additional layer onto an
existing roll stock of paper, foil or film. For example, this process can be used to improve
the characteristics of paper by coating it with polyethylene to make it more resistant to
water. The extruded layer can also be used as an adhesive to bring two other materials
together.

1.4.6 Compound Extrusions

Compounding extrusion is a process that mixes one or more polymers with additives to
give plastic compounds. The feeds may be pellets, powder and/or liquids, but the product is
usually in pellet form, to be used in other plastic-forming processes such as extrusion and
injection molding. Machine size varies from tiny lab machines to the biggest extruders in
the industry, running as much as 20 tons per hour, as used by the chemical companies that
make the base resins. Usually twin-screw extruders are preferred because they give better
mixing at lower melt temperatures. Most of these have screws and barrels made up of
smaller segments (mixing, conveying, venting and additive feeding) so that the design can
be changed to meet the production and product needs. Single-screw extruders can be used
for compounding as well, especially with appropriate screw design and static mixers after
the screw. Selection of the components to be mixed (viscosities, additive carriers) is as
important as the equipment.

12
 CHAPTER TWO
EXTRUDER SCREW

13
 CHAPTER TWO

EXTRUDER SCREW

2.1 Introduction

A numerous range of extruder screws are these days available for processing different
materials like polymers, metals or rubber. The screw is actually a long shaft that has a
thread helically wrapped around it. The thread is known as a flight. A channel in an
extruder screw refers to the area in between adjacent sections of the flight. Figure 2.1
shows a blown film extruder with die.

Figure 2.1 High performance blown film extruder with die (Photo: Windmoller and Holscher,
Lengerich, Germany)

2.2 Basic extruder types

Extruders may be divided into three general types:

 Single Screw Extruder

 Twin or Multiple Screw Extruder
 Ram Extruder

Single screw extruders and twin screw extruders are the most widely used extruders. The
screw that is used to push the resin out of the die is the important component of a screw
extruder.

2.3 Functions of an extruder screw

The extruder screw serves the following basic functions:

 Bringing the feedstock into the extruder and then moving the material along the screw.
This is performed side by side while compressing and removing volatiles.
14
 Softening of the melt by heating (from both internally generated shear forces as well as
externally applied heat).
 Pump the fluid in a steady manner.
 Mixing and melting to eventually produce a homogeneous melt that is without any
impurity.
 Applying constant pressure (free of any pulsation) very much needed for forcing the
material through the die.

2.4 Advantages of screw

An extruder screw enjoys the following advantages:

 An Increase in the melting efficiency due to total elimination of solids bed breakup.
 A considerably higher melting rate due to prolonged exposure of the solids bed to the
barrel surface where melting takes places.
 Better stability, due to complete elimination of channel plugging that is a source of
trouble at the entrance to the barrier section.
 Improved mixing in the melt channel as melt material is subjected to moderate shear
when it passes over the barrier flight.

2.5 Screw Design

In order to select the proper screw design for a particular resin (or resins), a basic
understanding of screw design variables and their effect on processing is
essential. Excluding the use of multiple flights (as used in barrier screws) and mixing
sections, there are five variables that may be utilized in the design of a metering screw that
have a bearing on how a solid resin becomes a melt. In addition to these variables, there
are barrier and mixing screw designs that can significantly affect processing results. Figure
2.2 shows the geometry of extruder screw

Figure 2.2 Geometry of extruder screw

15
2.5.1 L/D Ratio

The L/D ratio is the ratio of the flighted length of the screw to its outside diameter. The
ratio calculation is calculated by dividing the flighted length of the screw by its nominal
diameter.

The effect of changing the L/D ratio:

 The larger the ratio (longer flighted length), the more shear heat can be uniformly
generated in the plastic without degradation and greater the opportunity for mixing,
resulting in a better homogeneity of the melt;
 Greater the residence time of the plastic in the barrel possibly permitting faster cycles of
larger shots.

2.5.2 Screw profile

There are five possible zones in a thermoplastic screw. Since terminology is not
standardized in the industry, different names may refer to these zones. Different types of
polymer will have differing screw designs, some not incorporating all of the possible zones.

The standard metering screw has three zones as shown in Figure 2.3:

 Feed zone (solids conveying): This zone feeds the resin into the extruder, and the
channel depth is usually the same throughout the zone.
 Melting zone (transition/compression zone): Most of the resin is melted in this section,
and the channel depth gets progressively smaller.
 Metering zone (melt conveying): This zone, in which channel depth is again the same
throughout the zone, melts the last particles and mixes to a uniform temperature and
composition.

Figure 2.3 A simple plastic extrusion screw

In addition, as shown in Figure 2.4, a vented (two-stage) screw will have:

 Decompression zone: In this zone, about two-thirds down the screw, the channel
suddenly gets deeper, which relieves the pressure and allows any trapped gases (usually
moisture or air) to be drawn out by vacuum.
 Second metering zone: This zone is like the first metering zone, but with greater
channel depth, and repressurizes the melt to get it through the resistance of the screens
and the die.
16
 Figure 2.4 Schematic of vented extruder

The screw profile is described as the length, in diameters or flights, of each of the three
sections of the screw. General purpose screws typically use a 10-5-5 profile.

A 10-5-5 profile indicates 10 diameters in feed, 5 diameters in transition and 5 diameters in

meter. The length of each section has an impact on how a resin reaches a melt condition, as
follows:

 A longer feed section creates a greater potential throughput.

 A longer transition means less shear heat and more time to compress and melt the resin,
and the converse is also true.
 A longer meter section develops more pumping pressure vital to extrusion.
 A shorter meter means less time to assure an isothermal melt quality.

2.5.3 Compression Ratio

The ratio of the feed zone channel depth to the meter zone channel depth, referred to as
"compression ratio", typically ranges from 1.5:1 to 4.5:1 for most thermoplastic materials.

The higher the compression ratio, the greater the:

 shear heat imparted to the resin;

 heat uniformity of the melt;
 potential for creating stresses in some resins;
 Energy consumption.

2.5.4 Channel Depths

The channel depth in the meter zone of the screw is determined by the resin to be
processed. The feed and transition zone channel depths are dependent upon the selected
compression ratio and screw profile.

17
The channel depths influence the degree of shear heat developed by the screw and the
throughput of the screw. For example: a shallow screw channel:

 Increases exposure of plastic to heated barrel

 Increases the shear heat imparted to the resin
 Reduces the potential throughput of the screw.

A deep screw channel would have just the opposite effect, helping reduce the shear heat
and potentially increasing the throughput of the screw.

2.5.5 Helix Angle

The helix angle is the angle of a screw flight relative to a plan perpendicular to the screw
axis. Although the helix angle is not commonly altered from the standard square pitch,
such a change can have a significant impact on processing.

The standard helix angle is calculated as follows (a square pitch screw):

Helix Angle= arctangent of (Lead/ π x Diameter)

A change to a smaller helix angle, hence more flight turns per diameter:

 reduces the axial melting length;

 conveys stiffer materials with greater ease (and less torque);
 Reduces the rate at which material is conveyed.

Changes in the helix angle are more common in two stage screws and special mixing
screws than in metering screws.

2.6 Extruder Screw Materials

Extruder screws are mostly made up of alloy steel and then undergo further secondary
treatment operations depending upon the nature of steel. Some of these treatments include
chrome plating, nitriding, flight surface hardening etc.

2.7Extruder Barrel

The extruder barrels are part of the extruder machines used in the production of profiles and
other shapes. They are manufactured using extremely hard-wearing as well as corrosion
resistant materials which are often bimetallic.

The barrel is typically wrapped with heater bands, or with cast-aluminum heaters as shown
in Figure 2.5 to provide an improved heat distribution. The lining of the barrel is heat
treated and typically lined with a material for increasing the wear as well as resistance to
18
corrosion. Extruder barrels are made with wall thickness of at least 25 mm. This ensures
that the barrel is able to withstand pressures generated in the extrusion process. Small
clearances are essential between screw flights and the barrel wall for preventing back flow
of molten resin and a possible surge in the out put of the extruder.

Figure 2.5 Extruder Barrel

19
 CHAPTER THREE
REGENERATION TECHNIQUES

20
 CHAPTER THREE

REGENERATION TECHNIQUES

3.1 Introduction

Regeneration is the technique of welding, coating or metallising new or worn parts to

combat wear, corrosion, or to build up a part to a larger size, or to repair a machining error
or a casting defect. This technique has been used in this study to repair worn extruder
screws and improves its service life by applying a regeneration material (or materials) on
the major outer diameter surface of the screw.

3.2 Diffusion Coating

Diffusion coating, or metallic cementation, is the process of impregnating the surface of

steel with aluminum, chromium, silicon, boron, beryllium and other elements.

Diffusion coating is accomplished by heating and holding steel parts in direct contact with
one of the above elements which may be in solid, liquid or gaseous state.

This process imparts a number of valuable properties to steel, among which are high heat,
corrosion and wear resistance so this process is called chemical heat treatment.

The diffusion coating processes:

 Beryllisation
 Borisation (boronisation)
 Calorising (alitising)
 Chromising
 Molybdenising, Tungstenising, and vanadising respectively
 Siliconising

3.3 Thermal spraying

Thermal spraying or metallising techniques as shown in Figure 3.1, are coating processes in
which melted materials are sprayed onto a surface. The feedstock (coating precursor) is
heated by electrical (plasma or arc) or chemical means (combustion flame).

Thermal spraying can provide thick coatings (approx. thickness range is 20 micrometers to
several mm, depending on the process and feedstock), over a large area at high deposition
rate as compared to other coating processes such as electroplating, physical and chemical
21
vapor deposition. Coating materials available for thermal spraying include metals, alloys,
ceramics, plastics and composites. They are fed in powder or wire form, heated to a molten
or semi-molten state and accelerated towards substrates in the form of micrometer-size
particles. Combustion or electrical arc discharge is usually used as the source of energy for
thermal spraying. Resulting coatings are made by the accumulation of numerous sprayed
particles. The surface may not heat up significantly, allowing the coating of flammable
substances.

Coating quality is usually assessed by measuring its porosity, oxide content, macro and
micro-hardness, bond strength and surface roughness. Generally, the coating quality
increases with increasing particle velocities.

Several variations of thermal spraying are distinguished:

 Combustion Jet spraying

 Detonation Gun spraying
 Electric Arc spraying
 Flame spraying
 Plasma Arc spraying

Figure 3.1 Thermal spraying processes

22
3.4 Surfacing

Surfacing or overlaying as shown in Figure 3.2 is a process of depositing one metal or alloy
over another (base metal) to improve its wear resisting properties like resistance to abrasion,
corrosion, or friction. The processes commonly used for surfacing are the fusion welding
processes like gas welding, arc welding, etc. it extends the service life of the product and
saves expensive material. This results in considerable economic gains.

Usually four variants of the process are recognized viz., cladding, build up, hardfacing, and
buttering to achieve corrosion resistance for chemical wear, wear resistance for physical
wear, and to rebuild worn components.

Figure 3.2 Surfacing processes

Surfacing can be done by number of welding processes:

 Electron beam welding (EBW)

 Electro-slag welding
 Explosive welding
 Flux cored arc welding (FCAW)
 Furnace Fusing
 Gas metal arc welding (GMAW)
 Gas tungsten arc welding (GTAW)
 Laser welding
 Oxy-acetylene welding
 Plasma welding
 Shielded metal arc welding (SMAW)
 Submerged arc welding (SAW)
 Surfacing by Dip-Transfer

23
 CHAPTER FOUR
PREVIOUS INVENSIONS AND CASE STUDY

24
 CHAPTER FOUR

PREVIOUS INVENSIONS AND CASE STUDY

4.1 Previous Inventions

 Cobalt or nickel based alloys containing particles of high hardness such as tungsten
carbide. It has been determined that tungsten carbide particles have a tendency to wear
other steel and stainless steel parts. Tungsten is also very expensive and difficult to
obtain on a regular basis.
 Ceramic materials have applied to provide abrasion resistance to the flight surfaces of
conveyor screws. While alumina one of the hardest materials known, it’s expensive and
time consuming. Such material also does not provide a smooth flight surface, which can
bind plastic particles and increasing frictional contact.
 Suitable corrosion resistant alloys contain alloy steels, cast or wrought iron, low and
high carbon steels, nickel based alloys and stainless steel.
 In certain applications, copper and aluminum base alloys may also be suitable.
 Wear resistance coating materials include: chromium oxide, aluminum oxide, alumina
titania, zirconium oxide, magnesium zirconate, yttria-stabilized zirconium oxide, and
magnesium aluminate, tungsten carbide, tungsten chromium carbide, chromium
carbide, and tungsten titanium carbide.
 Ceramic coating can be applied by oxygen acetylene powder, oxygen acetylene rod,
detonation gun, plasma, or electron beam vapor deposition. Atypical operation includes
cleaning the surface, such as by vapor de-greasing, oven baking, ultrasonic cleaning,
etc. Coating will not adhere to surfaces that are not properly cleaned and roughened.
Surface roughening is desirably employed after cleaning, and can consist of abrasive
grit blasting, such as with aluminum oxide, angular steel grit, and silicon carbide.
Following surface roughening, the desired regeneration layer can be applied. In the final
operation, the regeneration layer is mechanically finished. Since a ceramic coating is
usually harder than most metals, the thermal stress build up must be avoided during
finishing. Ceramic are also known to be brittle, and can easily crack during finishing
operations. Precision grinders are the most common tool used in finishing a ceramic
coating. Lapping and grinding are two widely used finishing alternatives.

25
4.2 Case Study
In present study, the extruder screws include a base alloy steel screw body. It’s a single
screw extruder in blown film extrusion.

Harder materials are more likely to have lower thermal expansion, so the regeneration
material must have a coefficient of thermal expansion which is lower than the base alloy
screw body.

It must be hard surfacing materials. It provides wear resistance, friction reduction,

corrosion resistance, erosion resistance, and non-magnetic properties.

The molten plastic can range from 200 °C to 275 °C, so the regeneration material must
have a melting point above 275°C.

This study presents twenty regeneration materials compared to the base material of the
extruder screw as shown in table 4.1. These materials are:

1. Aluminum oxide (alumina Al2O3)

2. Babbitt (tin base alloy)
3. Brass (copper zinc alloy)
4. Brightray (nickel chromium alloy)
5. Bronze
6. Chromel (nickel chromium alloy)
7. Chromium carbide (Cr3C2)
8. Chromium oxide
9. Inconel (nickel chromium alloy)
10. Magnesium aluminum oxide (magnesia spinel MgAl2O4 )
11. Magnesium oxide (MgO)
12. Monel (nickel alloy)
13. Nichrome (nickel chromium alloy)
14. Nickel aluminide (Ni3Al)
15. Stainless steel
16. Stellite (cobalt chromium alloy)
17. Titanium dioxide (Titania TiO2)
18. Tungsten carbide (carbide WC)
19. Zirconium dioxide (ZrO2)
20. Zirconium silicate (ZrSiO4)

Figures 4.1& 4.2 show an example of worn screw before and after the regeneration process
to show the meaning of the study.

26
 Figure 4.1 Worn Screws

Figure 4.2 Regeneration Process: Welding of flights

27
28
CONCLUSION

29
 CONCLUSION
The blown film line is used for producing high quality, flexible mono and multi-layer flat
film using the blown film principle. The prepared thermoplastic melt that comes out of the
extruders is shaped into a ring-shaped tube via an extrusion tool-piece. The film tube is
flattened by draw-off and collapsing station and is then wound up into rolls, in ready to use
sizes, on a winder.

To repair worn extruder screws and improves its service life by applying a regeneration
material (or materials) on the major outer diameter surface of the screw. This study
involves twenty materials, which are studied theoretically. There are twelve materials are
suitable to use, as they are harder than the base material of the studied screw and overcome
the high temperature of the extrusion process.

The twelve materials are:

 Aluminum oxide
 Brightray
 Chromel
 Chromium carbide
 Chromium oxide
 Magnesium aluminum oxide
 Magnesium oxide
 Stellite
 Titanium dioxide
 Tungsten carbide
 Zirconium dioxide
 Zirconium silicate

The present study can be improved by adding new materials and using other conditions to
such as cost. These improvements will be more effective and available to carry out.

30
REFERENCES

31
 REFERENCES
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32
 ‫د‪ .‬ابراىيم سالم منصٌر‪ ،‬ىندسو التاّكل ًالطرق الفنيو فَ التصدٍ لو‪ ،‬دار الراتب الجامعيو(‪.)8222‬‬ ‫‪.82‬‬
‫د‪ .‬عبدالرزاق اسماعيل خضر‪ ،‬فيسياء المعادن‪ ،‬الجامعو التكنٌلٌجيو مركسالتعريب ًالنشر‪ ،‬بغداد (‪.)2228‬‬ ‫‪.82‬‬
‫محمد اسماعيل عمر‪ ،‬الطالء الكيربَ للمعادن ًالبالستيك‪ ،‬دار الكتب العلميو للنشر ًالتٌزيع‪ ،‬القاىره‬ ‫‪.02‬‬
‫(‪.)8222‬‬

‫‪33‬‬

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