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Right: Xaloy MPX technol- ogy is designed for abrasion protection in compounds with filler loadings up to 35%


machinery | Wear protection Extreme Coatings says that what it refers to as its


FliteGuard “conversion-to-carbide” process allows a deteriorated feed screw (single or twin) to last three to four times longer than a standard bi-metallic feed screw. The process involves application of its CarbideX coating to the screw flight land, where its fine particle size and post application finishing means adhesive wear is minimised. The company guarantees that the FliteGuard converted feed screws will wear at one-half the rate or less of any standard bi-metallic treatment. It claims that ASTM G-77 adhesive wear tests indicate wear can be reduced by three to five times. Kvinge says that users of FliteGuard screws also


benefit from an extension of barrel life. “Common hard facing materials are weld applied to feed screw flight lands. There are two main types used - Stellite (cobalt-based) and Colmonoy (nickel-based). On new feed screws, Plasma Transferred Arc (PTA) is used to apply tungsten carbide containing alloy (Colmonoy 83). PTA produces a high temperature to create a melt pool of steel into which the alloy is deposited. For the carbides to survive this high temperature encounter, large particle size tungsten carbides are required (50-150 microns). The result is a deposit with relatively large carbides surrounded by a sea of much softer binder. As the soft binder erodes, the hard, raised carbides are exposed. Such a deposit requires a highly wear resistant barrel liner to ‘protect’ from scoring by these hard carbides,” he says. “The carbide volume percentage in a standard


carbide PTA deposit is approximately 20%. In contrast, FliteGuard carbide is 80 volume%, which means much less soft material to erode. CarbideX particle size is also greatly reduced (0.6-5.0 microns), and the tem- perature during application never exceeds 135°C. This combination of fine particle size and high volume percent means that any barrel liner can be used with FliteGuard with no fear of feed screw contact wear. In the case of high abrasive filler content, a high quality liner is recommended,” Kvinge says. Extreme Coatings–which markets its coatings


through distributor partners to ensure consistency–says a recent FliteGuard profject for a PVC pipe extrusion customer improved component wear life by 225% and


Figure 1: Abrasion performance of Xaloy X-8000 and MPX coatings against standard HVOF thermal spray


Wear Coating


Xaloy X-8000 Xaloy MPX


Standard HVOF Abrasion Corrosion


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Impact


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Bond


Resistance Resistance Resistance Strength ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦


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Source: Nordson Corporation 70 COMPOUNDING WORLD | August 2017


increased productivity by 10-15% due to more consist- ent output. A foamed PVC profile extrusion application resulted in a feed screw wear life increase of 600% and saved an estimated $500,000 in annual material costs due to more efficient processing performance (efficien- cy drops as screw surfaces wear, the company says). For the same reason, FliteGuard allowed average output gains of 100 kg/h during a four-month trial against a standard hard facing in an HDPE pipe extrusion application. Steadily growing demand for highly filled and


reinforced compounds is also evident at Nordson Corporation. “For metal-replacement in automotive components, flame retardance in halogen-free wire and cable jacketing, and other stringent extrusion and injection moulding applications, increased filler loadings place ever greater challenges to the capacity of melt processing components like screws and barrels to resist abrasion and corrosion,” says Mark Colella, Global Prod- uct Manager for the company’s Xaloy brand. “Standard coatings for such components, such as those applied by the process of high-velocity oxygen-fuel (HVOF) thermal spray, may fail to provide adequate protection from wear imposed by filled compounds, thus shortening the working life of the equipment or necessitating costly downtime while components are refurbished.” The company has developed a new protection


technology that uses tiny tungsten carbide spheres to provide a coating for single and twin plasticising screws that is said to resist abrasive and corrosive wear better than standard coatings applied by HVOF thermal spray. Called Xaloy MPX thermal spray coating, it is comprised of particles measuring just five microns in diameter. These particles consist primarily of tungsten carbide and are six to seven times smaller than those used in standard HVOF coatings. They are also more densely packed owing to the uniform spherical shape resulting from a controlled plasma production process. The combination of the MPX coating’s ultra-fine


www.compoundingworld.com


PHOTO: NORDSON CORPORATION


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