Industrial Screw and Barrel Wear Resistance: A Materials Comparison Guide
In the plastics processing industry, the life and performance of a screw and barrel is largely determined by the material it is made of. Wear resistance is particularly important in high-volume, high-recovery or abrasive material applications. This guide compares the most commonly used materials for industrial screw and barrels: 38CrMoAlA, SKD61 and bimetallic alloys.
- 38CrMoAlA: General Industry Standard
Material Overview:
38CrMoAlA is a high-strength nitrided steel widely used for standard extrusion and injection molding screw and barrel applications. Its popularity stems from its balance between cost and performance.
Wear Resistance: ★★★☆☆
After proper nitriding (surface hardness can reach 900-1000 HV), it has moderate wear resistance and can be used to process non-reinforced plastics such as PP, PE and PS.
Corrosion Resistance: ★★☆☆☆
Not suitable for corrosive materials or those containing additives that release hydrogen chloride gas (e.g. polyvinyl chloride).
Best Applications:
General purpose extrusion
Injection molding of virgin plastics
Economical applications
- SKD61: High heat and wear resistant alloy tool steel
Material Overview:
SKD61 (equivalent to H13 in the United States) is a high alloy tool steel with excellent hot strength and hardness retention.
Wear resistance: ★★★★☆
SKD61 can reach a hardness of HRC 48-52 after proper quenching and tempering. It is more wear resistant than 38CrMoAlA, especially under high temperature and high shear conditions.
Corrosion resistance: ★★★☆☆
Better than nitrided steel, but still not suitable for highly corrosive plastics unless treated or coated.
Best Applications:
Engineering plastics (e.g. PA, PC, PBT)
High temperature extrusion
Long cycle injection molding
- Bimetallic screw barrel: Tungsten carbide or Colmonoy alloy is used to achieve extreme wear resistance
Material Overview:
A wear-resistant alloy layer is bonded to the inner bore surface of the bimetallic barrel. Common alloy choices include nickel-based Colmonoy 56 or tungsten carbide.
Wear resistance: ★★★★★
This is the preferred solution for extreme wear scenarios. Hardness up to 60-68 HRC. Ideal for fiberglass, flame retardant materials and recycled plastics.
Corrosion resistance: ★★★★☆
Nickel-based alloys offer excellent resistance to chemical corrosion, especially when combined with tungsten carbide.
Best Applications:
Fiberglass or Mineral Filled Plastics
Recycled Materials with Unknown Additives
High-Volume Extrusion Lines
Screw and Barrel Material Properties Comparison Chart
Material Wear Resistance Corrosion Resistance Typical Hardness Cost Effectiveness
38CrMoAlA ★★★☆☆ ★★☆☆☆ ~1000 HV (Nitrided) ★★★★★
SKD61 (H13) ★★★★☆ ★★★☆☆ 48–52 HRC ★★★★☆
Bimetallic ★★★★★ ★★★★☆ 60–68 HRC ★★☆☆☆
Which Should You Choose?
For Standard Applications: 38CrMoAlA remains a cost-effective and reliable choice.
For Tough Engineering Resins: SKD61 provides the required durability under thermal stress.
For Abrasive or Recycled Materials: Choose a bimetallic barrel with tungsten carbide to minimize downtime and maximize service life.
📩 Looking for expert advice or a custom quote?
Zhoushan Juyuan Plastic Machinery Co., Ltd. manufactures and customizes screw barrels using the three materials mentioned above to meet your extrusion or injection molding needs. Contact us today and we will provide professional advice based on your specific production needs.
📧 Email: cxj.job@gmail.com
🌐 Website: www.juyuan-machinery.com
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