The Science of Durability
Explore our advanced hardening processes for rock-steady hardness and unparalleled wear resistance.
PLC Gas Nitriding
Our PLC-controlled gas nitriding is a precision thermochemical process. By diffusing nitrogen into the surface of alloy steels, we create a hardened case layer (case depth) that significantly enhances wear resistance, fatigue strength, and corrosion protection. This isn’t just a coating; it’s a metallurgical transformation of the component’s surface.
PLC Gas Nitriding
Our PLC-controlled gas nitriding is a precision thermochemical process. By diffusing nitrogen into the surface of alloy steels, we create a hardened case layer (case depth) that significantly enhances wear resistance, fatigue strength, and corrosion protection. This isn’t just a coating; it’s a metallurgical transformation of the component’s surface.
RK 9999 – The Lightning Series
High-Velocity Oxy-Fuel (HVOF) coating is our premium solution for the most extreme wear environments. We propel powdered tungsten carbide at supersonic speeds, creating an exceptionally dense, well-bonded, and wear-resistant coating. The RK 9999 “Lightning” series is the result, offering unparalleled protection against abrasive fillers like glass fiber, calcium carbonate, and talc.
RK 9999 – The Lightning Series
High-Velocity Oxy-Fuel (HVOF) coating is our premium solution for the most extreme wear environments. We propel powdered tungsten carbide at supersonic speeds, creating an exceptionally dense, well-bonded, and wear-resistant coating. The RK 9999 “Lightning” series is the result, offering unparalleled protection against abrasive fillers like glass fiber, calcium carbonate, and talc.
Extrumax
ExtruMax is our proprietary coating technology specifically engineered for screws operating in high-wear environments. It provides a robust, low-friction surface that stands up to the most abrasive fillers, such as high levels of calcium carbonate or glass fiber. By protecting the screw’s critical flight geometry, ExtruMax ensures process stability and dramatically extends component life.
ExtruMax is our proprietary coating technology specifically engineered for screws operating in high-wear environments. It provides a robust, low-friction surface that stands up to the most abrasive fillers, such as high levels of calcium carbonate or glass fiber. By protecting the screw’s critical flight geometry, ExtruMax ensures process stability and dramatically extends component life.
Extrumax
At a Glance: Which Process is Right for You?
| Feature | PLC Gas Nitriding | RK 9999 — The Lightning Series | ExtruMax |
|---|---|---|---|
| Primary Benefit | Through-hardness, fatigue strength via diffusion case | Extreme surface wear resistance from dense WC HVOF overlay | High abrasion & filler resistance using sub-micron WC overlay |
| Material / Chemistry | Thermochemical diffusion (ε/γ’ nitrides in alloy steel) | WC–Co/Ni HVOF coating; crack-free, ultra-dense | Sub-micron WC–Co/Ni HVOF coating for fine abrasive media |
| Hardness (Typical) | 65–70 HRC | ~68–72 HRC equivalent (overlay) | ~68–72 HRC equivalent (overlay) |
| Wear Resistance | Excellent (general duty) | Exceptional (broad abrasive duty) | Superior (tuned for fine, high-abrasive fillers) |
| Corrosion Resistance | Very good | Excellent | Very good |
| Surface Finish after Polish | Ra ~0.2–0.4 µm achievable | Ra ~0.2–0.3 µm (mirror-grade) | Ra ~0.2–0.3 µm (mirror-grade) |
| Layer Type / Thickness | Diffusion case (no added thickness) | Dense sprayed overlay, typically 100–250 µm | Dense sprayed overlay, typically 100–250 µm |
| Bonding / Integrity | Metallurgical diffusion | Very high bond strength; low porosity; crack-free | Very high bond strength; optimized particle size for compactness |
| Best For | General purpose screws, barrels, tips; moderate fillers | Broad resin range; screws, tips & mixing zones facing abrasion/erosion | High-volume lines running fine abrasive or filled blends (CaCO₃, talc, glass, TiO₂) |
| Not Ideal For | Very high slurry-type abrasion; heavy regrind/filler | Sustained >500 °C or purely corrosive duty without abrasion | Coarse-particle impact abrasion with low filler content |
| Refurbishability | Re-nitriding after re-machining | Re-grind & re-coat (keeps geometry in spec) | Re-grind & re-coat (keeps geometry in spec) |
| Compatibility | Screws, barrels, tips/nozzles | Screws, tips, wear rings, barrier/mixer zones | Screws, tips, high-wear feed/convey zones |
Positioning Guidance
Choose PLC Gas Nitriding when you want robust, economical through-hardness and very good all-round life on general-purpose duties.
Choose RK 9999 when you need maximum, broad-spectrum wear protection on screws/tips across varied resins and operating conditions—without emphasizing high-filler duty.
Choose ExtruMax for fine-particle, highly abrasive blends (masterbatch, CaCO₃/talc/glass), where sub-micron WC gives the best retention of edge geometry and service life.