The Wear-resistant Extruder Crosshead/Screw for Wire Cable is engineered to revolutionize wire and cable manufacturing by delivering unparalleled durability and precision.
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Designed specifically for high-pressure extrusion processes in demanding industrial environments, this component addresses the long-standing challenge of frequent equipment replacement due to material abrasion. Its robust construction features a SAE 1006 carbon steel core reinforced with a nickel-chromium-tungsten alloy coating (HRC 58-60), a material combination validated through 1,200+ hours of accelerated wear testing. This innovative design provides 3-5 times longer lifespan compared to conventional sintered components, directly translating to reduced maintenance costs and increased production uptime. Ideal for handling high-viscosity materials, it ensures consistent material flow even in continuous 24/7 production cycles, making it indispensable for XLPE cable insulation, power cable sheathing, and high-temperature polymer extrusion applications.
Core Material: SAE 1006 low-carbon steel selected for its exceptional structural integrity and machinability, ensuring precise dimensional stability during high-pressure operations.
Coating: Nickel-chromium-tungsten alloy with microhardness of 4000-4200 DPH—a hardness level that exceeds industry standards for abrasion resistance. The alloy’s unique crystalline structure creates a self-lubricating surface that minimizes friction.
Surface Treatment: Advanced plasma spray welding process achieves uniform coating coverage with zero porosity, verified through ultrasonic testing to eliminate hidden defects.
Temperature Resistance: Sustains optimal performance at temperatures up to 350°C, with thermal expansion coefficient controlled at ≤12×10??/°C to prevent dimensional distortion.
Pressure Rating: Handles 200 bar maximum working pressure, with pressure fluctuation tolerance of ±5% to maintain extrusion consistency.
Screw L/D Ratio: Customizable from 20:1 to 30:1 to accommodate varying material viscosity requirements, with optional mixing sections for enhanced polymer homogenization.
Compatibility: Seamlessly processes PVC, PE, XLPE, and silicone rubber, with material-specific screw profiles available for specialized applications.
Anti-corrosion Properties: Resistant to industrial chemicals, mineral oils, and UV radiation, validated through 500-hour salt spray testing per ASTM B117 standards.
Precision Machining: Achieves tolerance of ±0.01 mm across critical surfaces, ensuring concentric extrusion and reducing insulation thickness variation to ≤2%.
Power Cable Manufacturing
Delivers consistent performance for high-voltage XLPE cables (6-35 kV), where insulation uniformity directly impacts dielectric strength. Field data shows a 30% reduction in insulation defects compared to standard components.
Minimizes material waste by maintaining stable extrusion pressure, with material utilization rates improved by 15% in large-scale production.
Automotive Wiring
Ensures smooth sheathing for automotive wires exposed to extreme under-hood temperatures (-40°C to 150°C) and continuous vibration. Complies with ISO 6722 automotive cable standards.
Aerospace and Marine
Withstands saltwater corrosion and high mechanical stress in marine cable production, meeting DNV GL requirements for offshore applications. Ideal for shipboard wiring and subsea cable insulation.
Industrial Extrusion Lines
Enhances productivity in continuous extrusion processes for pipes, profiles, and cable jacketing, supporting production speeds up to 120 m/min without performance degradation.
Q: How does the coating affect extrusion performance?
A: The nickel-chromium-tungsten alloy coating reduces friction coefficient to 0.15 (vs. 0.3 for uncoated steel), allowing 20% higher extrusion speeds while maintaining material homogeneity. This results in lower energy consumption (up to 18% reduction in motor load) and improved surface finish with Ra values ≤0.8 μm.
Q: Can this crosshead be used with existing extruders?
A: Yes, it is compatible with 90% of standard extruders from leading manufacturers (e.g., Davis-Standard, Reifenh?user). For non-standard models, our engineering team provides custom adapters with 2-week turnaround time.
Q: What maintenance is required?
A: Conduct visual inspections for coating wear every 500 operating hours and perform ultrasonic cleaning of the flow channel monthly to remove residual polymer buildup. The alloy’s self-lubricating properties eliminate the need for regular lubrication.
Q: What certifications does this product hold?
A: It complies with ISO 9001:2015 quality management standards, undergoes CE testing for machinery safety, and meets RoHS requirements for restricted substances.
Designed specifically for high-pressure extrusion processes in demanding industrial environments, this component addresses the long-standing challenge of frequent equipment replacement due to material abrasion. Its robust construction features a SAE 1006 carbon steel core reinforced with a nickel-chromium-tungsten alloy coating (HRC 58-60), a material combination validated through 1,200+ hours of accelerated wear testing. This innovative design provides 3-5 times longer lifespan compared to conventional sintered components, directly translating to reduced maintenance costs and increased production uptime. Ideal for handling high-viscosity materials, it ensures consistent material flow even in continuous 24/7 production cycles, making it indispensable for XLPE cable insulation, power cable sheathing, and high-temperature polymer extrusion applications.
Core Material: SAE 1006 low-carbon steel selected for its exceptional structural integrity and machinability, ensuring precise dimensional stability during high-pressure operations.
Coating: Nickel-chromium-tungsten alloy with microhardness of 4000-4200 DPH—a hardness level that exceeds industry standards for abrasion resistance. The alloy’s unique crystalline structure creates a self-lubricating surface that minimizes friction.
Surface Treatment: Advanced plasma spray welding process achieves uniform coating coverage with zero porosity, verified through ultrasonic testing to eliminate hidden defects.
Temperature Resistance: Sustains optimal performance at temperatures up to 350°C, with thermal expansion coefficient controlled at ≤12×10??/°C to prevent dimensional distortion.
Pressure Rating: Handles 200 bar maximum working pressure, with pressure fluctuation tolerance of ±5% to maintain extrusion consistency.
Screw L/D Ratio: Customizable from 20:1 to 30:1 to accommodate varying material viscosity requirements, with optional mixing sections for enhanced polymer homogenization.
Compatibility: Seamlessly processes PVC, PE, XLPE, and silicone rubber, with material-specific screw profiles available for specialized applications.
Anti-corrosion Properties: Resistant to industrial chemicals, mineral oils, and UV radiation, validated through 500-hour salt spray testing per ASTM B117 standards.
Precision Machining: Achieves tolerance of ±0.01 mm across critical surfaces, ensuring concentric extrusion and reducing insulation thickness variation to ≤2%.
Power Cable Manufacturing
Delivers consistent performance for high-voltage XLPE cables (6-35 kV), where insulation uniformity directly impacts dielectric strength. Field data shows a 30% reduction in insulation defects compared to standard components.
Minimizes material waste by maintaining stable extrusion pressure, with material utilization rates improved by 15% in large-scale production.
Automotive Wiring
Ensures smooth sheathing for automotive wires exposed to extreme under-hood temperatures (-40°C to 150°C) and continuous vibration. Complies with ISO 6722 automotive cable standards.
Aerospace and Marine
Withstands saltwater corrosion and high mechanical stress in marine cable production, meeting DNV GL requirements for offshore applications. Ideal for shipboard wiring and subsea cable insulation.
Industrial Extrusion Lines
Enhances productivity in continuous extrusion processes for pipes, profiles, and cable jacketing, supporting production speeds up to 120 m/min without performance degradation.
Q: How does the coating affect extrusion performance?
A: The nickel-chromium-tungsten alloy coating reduces friction coefficient to 0.15 (vs. 0.3 for uncoated steel), allowing 20% higher extrusion speeds while maintaining material homogeneity. This results in lower energy consumption (up to 18% reduction in motor load) and improved surface finish with Ra values ≤0.8 μm.
Q: Can this crosshead be used with existing extruders?
A: Yes, it is compatible with 90% of standard extruders from leading manufacturers (e.g., Davis-Standard, Reifenh?user). For non-standard models, our engineering team provides custom adapters with 2-week turnaround time.
Q: What maintenance is required?
A: Conduct visual inspections for coating wear every 500 operating hours and perform ultrasonic cleaning of the flow channel monthly to remove residual polymer buildup. The alloy’s self-lubricating properties eliminate the need for regular lubrication.
Q: What certifications does this product hold?
A: It complies with ISO 9001:2015 quality management standards, undergoes CE testing for machinery safety, and meets RoHS requirements for restricted substances.
