The Concept
Surface Engineering's Extreme Coatings process utilizes emerging Thermal Spray technologies to apply to
feedscrews extremely wear resistant coatings to virtually any size injection molding or extrusion feed screw.
This process provides crack free coatings with hardness values ranging from 55-75 on the Rockwell "C"
scale in thickness from 0.003"-0.050". Proprietary compositions of various Carbides, Ceramics, and Alloys
are incorporated to achieve abrasion resistant characteristics unmatched by any of the conventional hardfacing alloys
popular today! This process completely eliminates the necessity for Chrome Plating, Flame Hardening, or Nitriding, as
the entire feed screw surface is coated, including the root and flite sides. The coatings are much more wear resistant
than any of the three aforementioned processes, which makes the process excellent for feedscrews exposed to fiber
filled compounds. Furthermore, the process requires no preheat of post heat procedure, and during application,
components rarely exceed temperatures of 350°F. The low heat input helps prevent distortion, minimizing costly
straightening and/or machining time. It also allows for the repair of D-2 Tool Steel components, typically scrapped
when completely worn.
Preparation for screw rebuilding requires only touch up work and the removal of old Chrome before
the coating application. Another unique aspect of the process is the "Dualcoat" concept. This targets those
who require extreme wear resistance through the root of a feed screw, but whose barrels may not be compatible with the
hardness of the root coating. In this case, the flights may be coated with a more traditional product, but will be
masked during application of the harder root coating, thus eliminating compatibility issues and maximizing feed screw
life. It also must be noted that today's popular hardfacing alloys can be applied via the Extreme Coatings process with
an improvement in feed screw life. This is due to the elimination of base metal dilution inherent to welded overlays.
Other applications where this process is currently utilized includes Turbine Components, Bushings, Shafting,
Mixer Blades, Augers, Conveyor Screws, Chutes, Fan Blades, Conveyors, Slurry Pumps, and many other applications where
extreme conditions of wear exist.h jobs welcome for worn out and broken feed screws and barrels. Losing production, check your wear today.