CF/PEEK Starwheel (Single-Screw Compressor)

The starwheel is one of the core components of a single-screw compressor, primarily functioning as a seal. The CF/PEEK composite starwheel is made of PEEK resin reinforced with high-strength, wear-resistant carbon fiber. It addresses the deformation and wear issues that commonly occur in high-temperature, high-pressure environments with materials like PEEK5600CF30 or other polyester materials. Compared to PEEK5600CF30, the CF/PEEK starwheel significantly improves service life, effectively reducing issues such as increased gaps between the screw and the starwheel, increased leakage, rapid decline in airflow, and higher energy consumption caused by wear over time.

When steel starwheels are used, their high thermal expansion coefficient necessitates a larger clearance between the starwheel and the screw, leading to higher leakage, reduced efficiency, and potential jamming, which can result in severe failures. Conversely, starwheels made of general composite materials quickly deteriorate under shear forces and mechanical friction during operation, leading to increased internal leakage, decreased efficiency, frequent maintenance, greater labor intensity, and higher maintenance costs.

PEEK, as a typical high-performance thermoplastic resin, exhibits outstanding properties. When combined with continuous carbon fibers, the two materials’ strengths are synergized, resulting in superior overall performance. Due to its excellent properties, continuous carbon fiber CF/PEEK thermoplastic composites are widely used in aerospace, medical, automotive, and other fields. This material is currently a focal point of research for universities, research institutions, and enterprises.

Advantages of Continuous Carbon Fiber CF/PEEK Composite Starwheels

1. Low Noise and Vibration:
   CF/PEEK starwheels operate quietly and with minimal vibration. The reasonable structure of the single-screw compressor ensures ideal force balance, resulting in low vibration. Additionally, water lubrication in the compression chamber and the absence of speed-increasing gears further reduce noise.
2. High Strength and Toughness:
   CF/PEEK offers excellent impact resistance, comparable to or better than aluminum alloys. The radial and axial forces on the screw are automatically balanced by gas forces, requiring the planetary gear to withstand these forces with sufficient strength and rigidity.
3. Wear Resistance and Self-Lubrication:
   CF/PEEK exhibits high wear resistance and a low friction coefficient, even at temperatures up to 250°C.
4. Dimensional Stability:
   CF/PEEK has excellent dimensional stability, better air-tightness, low thermal expansion, and a reduced risk of jamming.
5. Extended Service Life:
   CF/PEEK starwheels last longer and reduce maintenance frequency. As a consumable part, the CF/PEEK starwheel significantly reduces overall operating costs by over 50% compared to domestically produced PEEK carbon-fiber-reinforced starwheels.
6. Low Moisture Absorption:
   CF/PEEK has excellent hydrothermal resistance and retains good mechanical properties even under high temperature and humidity. Additionally, it demonstrates exceptional hydrolysis resistance and can withstand steam, water, and seawater.

Other Applications and Prospects for Continuous Carbon Fiber CF/PEEK Composites

1. Unidirectional prepreg tapes
2. Woven fabrics
3. Composite thick plates
4. PEEK corner pieces for aircraft
5. Medical device handles and aiming brackets
6. Aircraft seats (Toray)
7. Aircraft window frames
8. Aircraft doors
9. Protective covers for high-speed permanent magnet motors
10. Electromagnetic railguns
11. Bone plates and screws
12. Compressor starwheels
13. Fighter jet skins
14. Wing leading edges
15. Helicopter rods
16. Rocket supports
17. Subsea pipelines
18. Vacuum pump blades
19. Analyzer covers
20. Thrust and wear-resistant rings
21. Tripods
22. Drill pipe window covers
23. Digestion tanks
24. Hydrogen storage tanks
25. Rocket casings
26. 3D printing filaments