How to Extend the Lifespan of Twin Screw Extruder Elements in High Wear and Corrosion Conditions?

In fields such as solid-state battery slurry mixing, high-wear production, high-fill modification, and glass fiber reinforced engineering plastics, twin screw extruder elements face severe challenges from high abrasion and corrosion. Extending service life while maintaining production efficiency has become a critical concern in the industry.

Recently, ZHITIAN announced that its cold isostatic pressing (CIP) technology for extruder elements has entered the pilot production stage, promising significant improvements in wear and corrosion resistance, with an expected lifespan increase of over 30% compared to mainstream materials.

Industry Background: Dual Challenges of Solid-State Battery and High-Wear Applications

• Solid-State Battery Slurry Mixing : Fine, hard particles cause continuous abrasion on screw surfaces.
• High-Fill Modification : High ratios of fillers like CaCO₃ and TiO₂ accelerate screw wear.
• Glass Fiber Reinforced Engineering Plastics : Glass fibers exert strong cutting forces on metal surfaces, shortening material life.

In such conditions, conventional screw elements often show noticeable wear or corrosion within 1-3 months, affecting capacity and equipment stability.

ZHITIAN's Technical Approach

• New Alloy System : Developing screw element materials with special reinforcing phases to balance hardness, toughness, and corrosion resistance.
• Cold Isostatic Pressing (CIP) : High-pressure uniform compaction followed by densification sintering to achieve low porosity and high-density alloy structures.
• Precision Machining and Surface Enhancement : Combining high-precision gear grinding, polishing, and anti-corrosion coatings to further extend lifespan.

Synergistic Protection with High-Performance Barrel Alloys

ZHITIAN's mass-produced high-performance barrel alloys, ZT615, ZT625 , ZT715, ZT725, ZT735 nickel-based tungsten carbide and ZT818 cobalt-based tungsten carbide , manufactured by hot pressing and cold isostatic pressing respectively, have reached international advanced levels in wear and corrosion resistance. Future screw element materials will work in tandem with these barrel alloys to provide combined protection for critical extruder components, extending maintenance intervals and reducing downtime risks.

Manufacturing and Quality Assurance

• Temperature and Humidity Controlled Workshops : Ensure stable machining accuracy and reduce thermal expansion errors.
• High-Precision CNC Machining Centers : Control key dimensions within ±0.01 mm.
• Full-Process Quality Control : Covering incoming material inspection, metallographic analysis, hardness testing, and assembly verification.

R &D Progress and Market Applications

Currently, the new CIP-processed screw element materials are undergoing trial runs in solid-state battery slurry production lines and high-wear modified plastics factories. Mass production is expected by 2026, focusing on:

• Solid-state battery cathode and anode slurry production
• High-fill modifications (CaCO₃, TiO₂, etc.)
• Glass fiber reinforced engineering plastics (PA, PBT, PPS, etc.)
• Special polymers with high wear and corrosion requirements

About ZHITIAN

As one of China's leading extruder gearbox manufacturers and twin screw extruder parts suppliers, ZHITIAN offers a full range of gearboxes from models 20 to 177, as well as independently developed barrels, high-performance alloy materials, and screw elements. With a stable manufacturing system and global service network, ZHITIAN is driving the extruder industry toward higher efficiency, durability, and energy savings.