Extruder Screw Flight Repair

We work with brands including Milacron, Kraus Maffei, Welex, Maplin, Battenfeld-Cincinnati, Sterling, Werner Pfleiderer, Davis Standard, NRM, Coperion, and many more.

About Our Extruder Screw Flight Repair Services

The repair process for extruder screw flights at Screw And Barrel Repair begins with a meticulous inspection to assess the extent of wear and damage. Using advanced measurement techniques, such as laser scanning and micrometer checks, we precisely quantify the wear patterns and dimensional losses. This initial step is crucial for determining the exact scope of repair needed to restore the screw flights to their peak operational efficiency.

Following the diagnosis, our technicians implement a precise rebuilding strategy. We utilize specialized welding techniques, including tungsten inert gas (TIG) welding and plasma transferred arc welding (PTA), which are renowned for their ability to apply wear-resistant materials with high accuracy and minimal heat input. This is vital for maintaining the integrity of the screw’s base material while adding new material to the worn areas. The choice of filler material is tailored to the type of wear, be it abrasive, corrosive, or adhesive, ensuring a durable restoration.

Once the welding is complete, the flights are meticulously machined back to their original specifications. We employ CNC machining centers to achieve precise contours and clearances, ensuring that each flight’s profile matches perfectly with the barrel, thus optimizing the extrusion process’s efficiency. This step not only restores the functionality but also enhances the performance by improving the material flow and reducing shear stress on the polymer.

The final stage involves a thorough quality inspection and testing to ensure that the repaired screw operates seamlessly within its assembly. We perform tests under operational conditions, checking for vibration, alignment, and pressure consistency, confirming that the screw delivers optimal performance. This comprehensive approach not only saves significant costs compared to complete replacement but also extends the service life of the extruder, offering you a cost-effective solution that keeps your operations running smoothly.

With nearly five decades of expertise in the field, we stand as pioneers in developing the industry's standard processes for screw rebuilding. When you choose Screw and Barrel Repair, you're not just choosing a service provider; you're partnering with a team of dedicated professionals who are passionate about delivering superior quality and unmatched reliability. Experience the difference with Screw and Barrel Repair - where precision meets perfection, and your satisfaction is our top priority.

Our Extensive Extruder Repair Process

1. Completely clean and strip all chrome or nitride coatings for preparation, inspection, and measurements to evaluate the extent of repair needed for your extruder.
2. Measure the outer diameter (OD) of each flight to assess wear and inspect the root diameter.
3. Precision OD grind to remove all existing hard facing, preparing a new layer of material for your extruder screw repair.
4. Restore the root diameter to perfection, ensuring no pits, zits, or pinholes. We apply an 8RMS finish to the root at this point.
5. Apply coatings such as Hastalloy, C56, or other hard facing materials (5 options available) to the OD of all flights, building beyond the original size.
6. Precision side grinding to remove excess hard facing from flights, essentially trimming the added material from your extruder screw flights.
7. Utilize dye penetrant testing to identify any cracks, pinholes, etc., and perform necessary repairs.
8. Polish the entire screw to a 6RMS mirror finish in preparation for plating or nitriding.
9. Apply hard chrome plating, electroless nickel plating, or nitriding across the entire screw and buff to a 4/5RMS mirror finish. Comply with Military Spec QQC-320B & Military Spec Mil-C-26074B Class A Grade 1. For the most durable exterior coating in harsh environments, we recommend CEB coating: Chrome over Electroless Nickel, baked at 475 degrees for 3 to 5 hours. A 2-year warranty covers all CEB coatings against pitting, chipping, burning, etc.
10. Precision OD grind the flights to your specified size.
11. Inspect all sizes, straightness, root diameter, and prepare for the final buffing and polishing.
12. Complete the final inspection of all sizes and tolerances, and perform final buffing to a mirror finish. Prepare for shipping with crating, foam insulation, and metal banding to your dock.

The final product is an extruder screw repair that surpasses OEM specifications/tolerances and performs like new. Fully guaranteed for one year. Delivery time is half that of our competitors. We surpass OEM specifications for polish finish, hard facing strength, straightness, TIR, plating thickness, etc. Our extruder repairs outperform new extruders, offering better warranties and lower prices.

We rebuild your extruder either to the exact original size or make it oversized to match your current barrel. If built to size, the repair makes your extruder fully interchangeable with any barrel. If built to a specific size, it remains dedicated to that barrel until the next rebuild. If your extrusion barrel is honed oversized to 100% cleanup, we can rebuild your extruder to match. This option saves significant costs over a barrel relining, which is expensive and time-consuming. However, this means the extruder and barrel are fixed to each other until the next repair cycle.

Types of Injection Screws & Other Equipment We Specialize in Rebuilding