Zeiger Industries. High Performance Plasticizing Components

Transcription

1 Zeiger Industries High Performance Plasticizing Components

2 Zeiger Industries Plasticizing Components Mallard Z4 Non-Return Valves 22 mm - Up GP Screws manufactured internally 14 mm - 70 mm ZP Screws manufactured internally 14 mm 70 mm Bimetallic and WC Barrels Any size End Caps Bolt On or Thread On Nozzles and Nozzle Tips LSR Plug -N- Play Conversion Kits Polycarbonate Optimized Packages Continuous Taper Packages for RPVC and Fire Retardants Shutoff Nozzles Air, Hydraulic and Water Cooled (LSR)

3 Barrel and Screw Assembly

4 Mallard Z4 Valve Options 1. Standard High Abrasion Valve 2. Carbide Faced Valve 3. All Stainless Steel Valve 2 Options 4. Interlocking Spinner Valve 5. Nickel Alloy Valves for Fluoropolymers 6. Zpringlok self closing Valve

5 Why a 4 piece vs. 3 piece Valve Assembly Replaceable wear components Optimized materials for each of the 4 components High strength, 17-4 PH Stainless Steel Retainer Highly wear resistant, high hardness Front Seat Highly wear resistant, high hardness Check Ring High hardness D2 Rear Seat

6 4 Piece vs. 3 Piece Construction View

7 4 Piece vs. 3 Piece Valve Flow Path

8 Mallard Z4 vs. 3 piece Valve Features Standard Mallard Z4 Valve Assembly Standard 3 piece Valve Assembly 17-4 Stainless Retainer (36-40 HR/c) CPM M4 Front Seat (60-62 HR/c) CPM M4 Check Ring (60-62 HR/c) D2 Rear Seat (59-61 HR/c) H-13 Tip (50-53 HR/c) H-13 Check Ring * (50-53 HR/c) H-13 Rear Seat (50-53 HR/c) * Occasionally Nitrided

9 Mallard Z4 Sliding Ring Valve Options Parent Parts Retainer is 17-4 PH Stainless Steel H/Rc Rear Seat is D2 Tool Steel HR/c Replaceable Wear Components Front Seat is CPM M H/Rc Check Ring is CPM M H/Rc Front Seat is A-9 Tool Steel and Carbide Faced Check Ring is A-9 Tool Steel and Carbide Faced Front Seat is CPM S90V H/Rc Check Ring is CPM S90V H/Rc o Front Seat is Elmax PM Tool Steel H/Rc o Check Ring is Elmax PM Tool Steel H/Rc

10 Mallard Z4 Valve

11 Mallard Z4 Interlocking Spinner Valve Parent Parts Retainer is 17-4 Stainless Steel H/Rc Rear Seat is D HR/c Replaceable Wear Components Front Seat is A9 Tool Steel H/Rc Check Ring is A9 Tool Steel H/Rc

12 Mallard Z4 Interlocking Spinner Valve

13 Corrosive Challenges Additives Chlorides Fluorides Bromides Halogen Free Fire Retardants By-Products Hydrochloric Acid Hydrofluoric Acid Hydrobromic Acid Variety of Corrosives

14 Corrosive Attack

15 Wear Challenges Type of Additive Talc Mica Chalk Glass Fibers Glass Micro-Spheres Titanium Oxide Silica Aluminum Oxide Mohs Hardness Maximum Value of Scale is Diamond which is Rated at 10

16 Check Ring OD Wear

17 High Speed Processing Challenges High Screw Speeds Elevated Back Pressures High Viscosity Polymers All of the above mentioned conditions can generate excessive localized heating on the front seat and check ring causing premature failures

18 Typical Heat Related Failures

19 Additional Heat Related Failures

20 Additional Heat Related Failures

21 RPM Zeiger Recommended RPM Chart for Mallard Z4 Valves Screw Diameter

22 Hardness Concerns

23 Zeiger GP Screws All internally manufactured screws are either through hardened tool steel, carbide encapsulated or FliteGuard coated :1 Compression Ratio is Industry Standard 20, 22 and 25:1 L/D Ratio is common

24 Zeiger GP Screws

25 Industry Definition of a GP Screw: A compression screw with a feed, transition and metering zone representing 50, 25, 25 % of the flighted length respectively. The pitch or lead of the screw being equal to the diameter. A compression ratio between the feed and metering zone, between 2 to 4:1. Typical length to diameter ratio (L:D) that is between 16 and 25:1.

26 Superior Melting and Homogenous Mixing possible. Screw Technology Today Mixing screw technology: Pineapple Mixing Section Pulsar Mixing Section GP screw technology: METERING FEED LIMITATIONS! Expensive to manufacture. Mixer is very resin specific and unable to process a wide range of materials. GOOD FEATURES! Superior Melting and Homogenous Mixing possible. Barrier screw technology: LIMITATIONS! Various compression ratios and channel lengths, no Industry Standard! Does a poor job of melting. Does a poor job of homogenous mixing. POSITIVE ATTRIBUTES! LIMITATIONS! Expensive to manufacture Resin specific and unable to process a wide range of materials. POSITIVE ATTRIBUTES! Inexpensive to manufacture. Ability to process a wide range of materials.

27 Zeiger Performance (ZP) Screws All internally manufactured screws are either through hardened tool steel, carbide encapsulated or FliteGuard coated with XC1000 or XC1000Ni Available as follows: o o o Designs specifically for a given resin Designs for a family of resins i.e. Crystalline Designs for processing an array of resins

28 The ZP Screw Theory The Zeiger Performance (ZP) screw is a direct replacement for a GP screw. We have proven that by altering the flight pitch and root of the screw through the metering section we can increase the plastic exposure to the barrel wall by up to 50%. This achieves improved melting and homogenization by disrupting the laminar flow that is prevalent in GP screw designs. Additionally, output is increased because the volumetric compression is low, while achieving a high linear depth ratio (the ratio between the feed depth and the meter depth).

29 ZP Theory continued The technology of exposing more resin to the barrel wall for conductive heat transfer has led to the development of more advanced ZP screw designs. Both resin specific, family specific or Multi-Material designs have been successfully placed into production. The improved melt pool is necessary in applications that require precise color matching and/or higher throughputs. Our technology, a core change to the geometry of a plasticizing screw, is the most versatile technology available in the world for delivering a high quality melt for the lowest possible cost.

30 Comparison: GP design vs. the ZP Screw 1. The channel volume of the GP screw is equal to the channel volume of the Posi-Melt screw in this section. 2. Equal channel volume with an increased lead equals a shallower flight depth.

31 Distributive and Dispersive Mixing The objective of Distributive Mixing is to mix the fluid by reorienting the flow many times while limiting the shear rate to acceptable levels. The objective of Dispersive Mixing is to break down the particle size of the filler to a certain critical size and to evenly distribute it throughout the fluid. In Dispersive mixing there will always be Distributive mixing.

32 Benefits of a Standard ZP Screw Increased throughputs of between 10-30% means quicker screw recovery times. Increased throughput enables a lower rpm for reduced heat generation and cooler melt temperatures. Cooler melt temperatures = decreased cooling time and lower cycle times. Negligible temperature overrides for complete control of your process. Better mixing capability = the ability to lower back pressure for cooler melt temperatures and less screw decompression. Versatility to process all resin groups.

33 Zeiger Rigid PVC Solutions All components are Corrosion Resistant Stainless Steels: Screws generally have a 2.2:1 Compression Ratio and the flight profile is 35/50/15 Check Ring Valves (RSP s) have increased flow and travel to minimize shear burning End Caps, Nozzles and Nozzle Tips all need to have a Continuous Taper design in flow path area We are the preferred component supplier to PolyOne customers who are processing their Geon RPVC

34 A Typical RPVC Conversion The customer was running 8-12% scrap on a 55 mm Battenfeld that was molding a highly polished kitchen appliance base (blender). The OEM end cap and 3 piece check ring valve had a 90 degree nose angle and a straight bore nozzle body with no replaceable nozzle tip The screw had a 3:1 compression ratio with roughly a 50/25/25 flighted profile

35 OEM 55 mm Battenfeld Mallard Z4 Valve Design

36 55 mm Battenfeld OEM End Cap

37 55 mm Battenfeld RPVC Continuous Taper Layout

38 55 mm Battenfeld Mallard Z4 RPVC Valve

39 55 mm Battenfeld RPVC Continuous Taper End Cap

40 17-4 Stainless Steel Continuous Taper Nozzle

41 55 mm Battenfeld Design Comparison

42 LSR Plug-N-Play Conversion Kits Water Cooled WC Lined Wexco 777 Barrel with tapped Feedport ZWear Zero Compression Ratio Screw ZpringLok Self Closing Valve Assemblies Barrel Sealing Kit Water Cooled End Caps if needed Water Cooled Pin Type Shut-Off Nozzle

43 WC lined Water Cooled LSR Barrel

44 Mallard Spring Actuated Zpringlok Valve

45 LSR Water Cooled Pin Type Shut-Off Nozzle

46 Clear Polycarbonate (PC) Processing Solutions All Primary Plasticizing Components are built of a PM Stainless Vanadium bearing Tool Steel Elmax Melt is always in contact with the Elmax Elmax offers better lubricity/release than other competitive steels It is neither Coated nor Nitrided Good Wear and Corrosion Resistance Significantly improves Clear PC production by eliminating material hang up that causes black specking and or streaking

47 Elmax Inserted End Cap for Processing Clear PC

48 Continuous Taper Nozzle

49 Beginners Metallurgy A look at the Steels used in the production of your Front End Components and how they are produced

50 Properties of Tool Steels Hardness resistance to deforming & flattening (compression) seating surfaces indent, screws and tips bend Toughness resistance to fracture, impact parts break Wear resistance resistance to abrasion & erosion Flights erode, surfaces scoured, seating surfaces gall Corrosion resistance resistance to chemical degradation tools rust, pit, dissolve

51 Tool Steel Design Matrix compositions can be altered to enhance toughness, hardness, heat resistance, corrosion resistance Carbide volume and composition can be altered to offer enhanced wear resistance usually at the expense of toughness and fabricability

52 Common Alloying Elements and what they do in Tool Steel Each individual element imparts certain specific properties to the steel, according to percentage. The effects of a single alloying element can be modified by the presence of other elements. Carbon symbol C This is the most important and influential alloying element in steel. With increasing carbon content, the strength and hardenability of the steel increase, but its ductility, formability, weldability, and machinability are decreased. Manganese symbol Mn Manganese is used as a deoxidizer. It contributes to strength and hardness, but to a lesser extent than carbon. Manganese has a strong effect on increasing the hardenability of steel by reducing the critical cooling rate. Nickel symbol Ni In combination with chromium, nickel produces alloy steels with greater hardenability. Nickel is not a carbide former.

53 Common Alloying Elements and what they do in Tool Steel Aluminum symbol Al This is the most effective and frequently used deoxidizer in steelmaking. Small additions are used to insure small grain size. Aluminum will form with nitrogen and form hard aluminum nitrides, which is why it is added to nitriding steels. Cobalt symbol Co Cobalt improves red hardness and high temperature strength, therefore it is frequently used in high-speed steels, hot forming tool steels, creep resistant steels, and high temperature materials. Cobalt does not form any carbides. Chromium symbol Cr Chromium is generally added to steel to increase resistance to corrosion and oxidation, to increase hardenability, and to improve high temperature strength. Chromium is a carbide former, which increases edge retention and wear resistance.

54 Common Alloying Elements and what they do in Tool Steel Molybdenum (abb. Moly) symbol Mo Molybdenum is usually alloyed together with other elements and is a pronounced carbide former. It increases temper brittleness and promotes fine grain formation. Molybdenum also increases weldability and increases the tendency for secondary hardening during tempering. Tungsten symbol W Tungsten is a very pronounced carbide former. It improves toughness and prevents grain growth. Tungsten increases high temperature strength and red hardness. It is primarily used in high speed steels and hot forming tool steels. Vanadium symbol V Vanadium is a pronounced carbide former, which increases wear resistance. It increases high temperature strength and resistance to softening.

55 Effect of chemistry on wear Alloy elements (Cr, Mo, W, V) form carbide particles in tool steel microstructure - Amount & type of carbides influence wear resistance HARDENED STEEL - 60/65 HRC CHROMIUM CARBIDES - 65/70 HRC MOLY, TUNGSTEN CARBIDES - 72/77 HRC (solid carbide ~ WC) VANADIUM CARBIDES - 82/84 HRC

56 Wear Resistance CARBIDE TYPES V MO, W, V CR MORE MORE MORE