TABLE OF CONTENTS

Introduction to Petrochemical Source ...... 6 How Are Plastics Produced? ...... 7-8 Terminology ...... 9 ... 12 CNC vs. Injection ...... 1.3-14 - Vacuum Forming ...... 15-16 Pressure Forming ...... 17-21

Engineering Plastics Materials ABS Roya lite® Sheet (Foldout) ...... 2.3-24 Acetron ® - GP Acetal ...... 2.5-26 Acetron ® - NS Acetal ...... 27-28 Acrylic ...... 29 CAB - (Celulose Acetate Butyrate) ...... 30 Celcon® Acetal Copolymer ...... 31-35 Delrin® Acetal Homopolymer ...... 36-37 Delrin® AF and Delrin® CL ...... 3 8 Ertalon® LFX ...... 39 Fluorocarbons ...... 4. 0-43 Fluorosint® 500 & 207 ...... 44 Fluorosint Properties ...... 45 Halar® - ECTFE ...... 46 Hydlar® - ECTFE ...... 4 7 Hydex™ 101, 202, 301, 302 ...... 48-49 Hydex® 4101 ...... 50-51 Kel-F™ - PCTFE ...... 52-53 Kydex® ...... 54 Kydex ® 6200 ...... 55 Kynar®...... 5.6-57 Laminated Plastics - Thermoset (Foldouts) ...... 58-61 Nylatron® - GS & GSM, MC-901 & 907 ...... 62 0 Nylatron® NS and Nylatron® NSM ...... 63 Nylon Comparative Properties ...... 64 Nylon 101 ...... 65

TABLE OF CONTENTS

Nylon Zytel® ST 801 ...... 66 - Machining Grades ...... 67 Properties of Polycarbonate & Glass Filled Polycarbonate ...... 68 Polycarbonate - Lexan® GP Sheet ...... 69 Polycarbonate - Lexan® Specialty Grades ...... 70 Polycarbonate - Lexan® Sheet Properties ...... 71 - UHMW ...... 72-73 Polyethylene - UHMW- Solidur® (Foldout) ...... 74 Polyethylene Terephthalate (PET) ...... 75 ...... 76 - PVC ...... 77 PVC - CPVC Physical Properties ...... 78 PVC - Mitech® M-104 ...... 79 PVC - Mitech® M-411 ...... 80 Rulon ® ...... 81-82 Rulon ® Properties ...... 83 Styrene ...... 84

High Performance Materials -imide - Torian® ...... 86-90 Polyarylsulfone (PAS) - Radel® ...... 91-92 Polybenzimidazole (PBI) Celazole® ...... 93 Polyetheretherketone - (PEEK) ...... 94 PEEK - Physical Properties ...... 95 PEEK- Bearing and Wear Data...... 96 PEEK - Chemical Resistance ...... 97 Polyetheretherketone - Comparative Charts ...... 98-99 Polyetherimide - Ultem® ...... 100 Polyetherimide - Ultem® Physical Properties ...... 101 - Envex® ...... 102 Polyimide - Envex® Physical Properties ...... 103 Polyimide - Vespel® ...... 104-105 Polyimide - Vespel® - Chemical Resistance ...... 106 Polyphthalamide (PPA) Amodei®...... 107

TABLE OF CONTENTS

Polyphynylene Oxide (PPO) - Noryl® ...... 108 Polyphenylene Sulfide (PPS) - Fortran®...... 109-110 Polyphenylene Sulfide (PPS) - Ryt on® ...... 111 Polyphenylene Sulfide (PPS) - Techtron® ...... 112-113 - UdeI® ...... 1.14-115

Technical Support Data Chemical Resistance Data ...... 117-121 Comparative Material Price Position...... 122 Plastics Bearing Design ...... 123-129 Plastics Gear Design ...... 130-139 U.L. Flammability Ratings ...... 140 Comparative Materials Chart (Foldout) ...... 141 Manufacturers List ...... 142

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We at Piedmont CMG proudly present our Guide. Two years of research and study went into its preparation. Our mission is to provide our customers with a complete and non-biased presentation on all plastics materials that are available in sheet, rod and form. These engineering materials must be chosen carefully by assessing the application requirements and the capabilities of each material. We hope that this book will be helpful to you in designing successful plastics applications. Our staff is available to assist you in selecting the proper material. At Piedmont CMG, we're people turning your ideas into products.

PETROCHEMICAL PLASTIC PRODUCTS SOURCE

PROPYLENE - - - ISOPROPYL ALCOHOL- - - ACETONE ., v• ,,,nc J-ACETONEC YANOH DR I N=J- - - HYDROGENCYANIDE METHYL METHARCRYLAT1 ------ACRYLIC METHANE------· - - - HYDROGEN--i

r-- METHANE L wwonc_lMETHYL ALCOHOt CARBON MONOXIDE n·BUTYLENE------BUTADIENE ------, ETHYLENE -- BUTOXY BENZENE ETHYL BENZENE STYRENE ------' j------ETHYLENE------ETHYL ALCOHOL - - - - ACETALDEHYDE------ACETIC ANHYDRIDE L CELLULOSE ACETATE --- CELLULOSE j ALDOL·ACETALDEYDE (SOURCE AS S ABOVE) WN - - ACETIC ANHYDRIDE (SOURCE AS SHOWN PROPYLENE------ABOVE) J-- CELLULOSE HYDROGEN OR n·BUTYRALDEHYDE · n-BUTYRIC ACID· n· BUTYRIC ANHYDRIDE ACETATE· METHANE ______,r-- BUTYRATE L_ CARBON MONOXIDE - CELLULOSE

PROPYLENE ALLYL CHLORIDE GLYCERINE DICHLOROHYDRIN - - - EPICHLOROHYDRINJ

PROPYLENE ------ISOPROPYLALCOHOL ACETONE 1 . -1------EPOXY

BENZENE B I SPHENOL · A BENZEN I OR '------rC1U1M' '•E1••EN======PHENOL PROPYLENE

TOLUENE HYDROGEN - - - - - , MELAMINE 7 , ______MELAMINE· METHANE ------J _J 1------METHYL ALCOHOt - - - - FORMALDEHYDE _J FORMALDEHYDE CARBON MONOXIDE

BENZENE BENZENE OR

PROPYLENE - - - - ; CU MENE- - -=- =-=-=- =-=-= = -=------PHENOL }-

PHENOLIC TOLUENE HYDROGEN - - - - - METHANE ------" I METHYL ALCOHOL ------FORMALDEHYDE CARBON MONOXIDE _i----

ETHYLENE- - - - _ _ _ _ _ STYRENE -: - --, BENZENE ------ETHYLBENZENE

BENZENE ORTHOXYLENE MALEIC ANHYDRIDE f------l f ------ OR! -:::= ------PHTHALICANHYDRIDE-- NAPHTHALENE" ETHYLENE ------ETHYLENE OXIDE ------ETHYLENE GLYCOL--- 1------' PROPYLENE PROPYLENE OXID PROPYLENE GLYCOL ETHYLENE ------POLYETHYLENE PROPYLENE POLYPROPYLENE ETHYLENE- - - - - BENZENE f------ETHYL BENZENE ------

METHANE ------ACETYLENE' ------POL YVI NY L

O - - - ------ETHYLENE ETHYLENE DICHLORIDE ------CHLORIDE ETHYLENE - - - - - 1------ETHYL BENZENE------STYRENE STYRENE· BENZENE------' BUTADIENE n-BUTYLEN BUTADIENE COPOLYMERS METH ANE- - - - r- HYDROGEN- - - , ______AMMONIA UREA - NITROGEN- - - UREA· FORMALDEHYDE METHAN _ - _ _ r- HYDROGEN } --- c CARBON MONOXIDE ------METHYL ALCOHOL------FORMALDEHYDE 9 >-- - - VINYL CHLORIDE METHANE ------ACETYLENE"------E- TH Y- LE -NE DICHLORIDEACETYLENE' ------, VINYL . .\ :;: : COPOLYMERS ETHYLENE - - - - ETHYL ALCOHOL - - - ACETALDEHYDE - - - - ACETIC ACID - - - - - U -_,. _ VINYL ACETATE -- ACETALDEHYDE (SOURCEAS SHOWN ABOVE) ACETALDEHYDE (SOURCE AS SHOWN ABOVE) ------ACETIC ANHYDRIDE ---

6

HOW ARE PLASTICS PRODUCED?

The chemical structure and the nature of plastic materials In general, narrow-range resins have better mechanical have a significant relationship not only to the properties of properties than broad-range resins, although, as with the the plastic but to the ways in which it can be processed, of the higher molecular weight materials, they are designed, or otherwise translated into an end-product. somewhat more difficult to process! Basically, all polymers are formed by the creation of In addition to the size of molecules and the distribution of chemical linkages between relatively small molecules or sizes in a polymer, the shapes or structures of individual to form very large molecules or polymers; the polymer molecules also play a major role in determining the same idea as connecting boxcars on a railroad to form a properties of a plastic. Polymers may align themselves into train, the boxcars being monomers and the train a polymer. long chains of molecules without any side branches, or Like boxcars, the molecules must have the ability to be lateral connections between molecules. However, it is coupled at either end. possible for polymers to form more complex structures. Thus, polymer molecules may form in the shape of Actually, in polymer formation, the process is more like branched molecules, in the form of giant three-dimensional forming many, many trains in a railroad yard simultaneously networks, in the form of linear molecules with regular lateral from the boxcars available in the yard in a competitive connections, and in the form of two-dimensional platelets. fashion. The train-forming process of polymerization comes Because of the geometry of such molecules, some can to a stop when factors prevent any additional boxcars from come closer together than others in which the structure being added. Thus, we ultimately end up with trains having prevents more intimate contact. Thus, polymers that can be a variety of lengths, yet all composed of the same kind of packed closely or exhibit little hindrance ordinarily can more boxcars. easily form crystalline structures in which the molecules are The above process is characterized by the simple aligned in some regular pattern. combination of molecules without the generation of any by­ Amorphous polymers do not have melting points, but rather products formed as a result of combination. In reality the softening ranges; are normally transparent; and undergo addition-type process can occur in several ways. One way only small volume changes when solidifying from the melt. simply involves the external chemical activation of Crystalline polymers, on the other hand, have considerable molecules that causes them to start combining with each order to the molecules in the solid state, indicating that other in a chain-reaction-type fashion (by the bonding of many of the other atoms are regularly spaced; have a true atoms directly within the reacting molecule). Another way for melting point, and have a relatively large volume change an additional polymerization to occur is through a during the transition from melt to solid. rearrangement of atoms within both reacting molecules, but still without the net loss of any atoms from the polymer Thus, many different structures are possible with plastics - molecule. A third way for additional polymerization to occur and each will affect the basic properties of the polymer. For is for a molecule composed of a ring of atoms to open up example, linear polymers, such as high-density and connect with other ring-type molecules being opened polyethylene, are made of molecules that resemble up under the influence of the proper catalytic activators, spaghetti in a bowl and are relatively free to slide over one once again with no net loss of any atoms from the polymer another or to pack more closely together (in the absence of structure. steric hindrances due to large pendant side groups). Branched polymers, such as low-density polyethylene, on Because there is such diversity among polymer molecules, the other hand, have side appendages and interconnections a number of techniques for defining and quantifying these that cause the molecules to resemble clumps of tree characteristics are in use by the industry - and are also of branches that cannot be easily compressed or compacted. value to processors and end-users as a determinant of Thus, branched polymers (with more voids) are more polymer properties. One such parameter relates to the size permeable to gases and solvents than linear polymers, of the molecules in the polymer and is known as molecular lower in density (since the molecules are not compacted weight. Molecular weight refers to the average weight of the together), and more flexible. Linear polymers, on the other molecules in the mixture of different size molecules that hand, are higher in tensile, stiffness, and softening make up the polymer. It is expressed either as a number temperatures. average, based on the sum of the number fractions of the weight of each species or size of molecule present. Cross-linked structures, in which the individual chain segments are strongly bound together by chemical unions, The molecular weight of a polymer has a significant effect also have special characteristics (as in the family of on its properties. Thus, higher molecular weight polymers thermosetting plastics). They do not exhibit creep or tend to be tougher and more chemically resistant. In the relaxation unless such primary bonds actually are broken by polyethylene family, for example, low molecular weight continually applied stress or by elevated temperatures high are almost waxlike in characteristics, whereas enough to cause chemical decomposition of the polymer. ultra-high molecular weight polyethylenes offer outstanding Cross-linked polymers also are fairly resistant to solvent chemical resistance and toughness (although, conversely, attack; solvents may swell such polymers, but seldom the higher the molecular weight is, the more energy in the cause complete rupture or dissolution. form of temperature and pressure required to process the material.) Ladder structures have unusual stability and have become important in terms of the new heat-resistant plastics. It is also important to know something about the molecular Aromatic compounds (such as benzene) and heterocyclic weight distribution within the polymer, that is, the relative compounds (such as benzimidazole) that have semiladder, proportions of molecules of different weight. If the resin is ladder, or spiro structures offer heat stabilities in excess of made up of chains close to the average length, it is called 900°F. narrow; if it is made up of chains of a wider variety of lengths, it is called broad. It should also be noted that whereas the effect of molecular weight and molecular weight distribution on properties is

7

HOW ARE PLASTICS PRODUCED?

relatively fixed and stable with temperature (barring Thermosetting plastics are polymeric materials with decomposition of the polymer), the arrangement of the structural frameworks that do not allow deformation or slip molecules within the structure of a polymer mass is in most to occur between molecular chains. They are composed of cases relatively sensitive to temperature. Thus, the structure strong, primary covalent bonds and may be thought of as of any given polymer can be significantly changed by one large molecule. exposing it to different temperatures and thermal treatments. In , only secondary van der Waals forces, dipoles, and hydrogen bonds exist between chains. In For example, heating a crystalline-type polymer above its thermosetting materials, heat is commonly used to cause a melting point and then quenching it can produce a polymer chemical reaction (polymerization) resulting in crosslinks that is far more amorphous or noncrystalline in structure between chains. While in a low molecular mass state, heat than the original polymeric sample. Such a quenched and pressure are commonly used to cause the material can have properties that are significantly different thermosetting material to flow into a mold cavity. from the properties of a sample that is cooled slowly and allowed to recrystallize. Once solidified, these materials may not be reshaped or formed by applying heat. These plastics have a permanent The effects of time on a polymer structure are similar to set once they have been polymerized. those of temperature in the sense that any given polymer has a "most preferred" or equilibrium structure in which it Thermosetting plastics are stronger than thermoplastics, would prefer to arrange itself, but it is prevented from doing and have a higher product-service temperature. so instantaneously on short notice by steric hindrances. Thermoplastics may hold many process advantages over However, given enough time, the molecules in a polymer thermosets, however. A major advantage is that ultimately migrate to arrange themselves in this form. thermoplastics may be ground and recycled into other Elevating the temperature and making the molecules more useful products. mobile or spreading them apart allows them to accomplish this in a shorter time and vice versa. Thus over an extended period of time, the properties of a polymer can become significantly different from those measured earlier if the structure of the polymer was in an unstable form when the properties were initially evaluated. Engineered plastics commonly refers to polymers used or tailored to end-product needs. Acetal, ABS (acrylonitrile­ butadiene-styrene), polyamide, polyamide-imide, polycarbonate, polysulfone, polyethersulfone, and polyarylsulfone are familiar examples. The term is also used for any polymer with physical properties good enough for use as structural materials. Advanced composites or engineered composites refer to the group of materials usually associated with aerospace structures. The word advanced infers that new, engineered reinforcements or matrices are being used rather than traditional reinforcements of glass with a matrix of polyester. Kevlar, carbon, and boron fibers in an epoxy matrix are used to produce aircraft structures, athletic equipment, and automobile components. All these terms denote an improvement in materials for producing high-performance products. There are a number of ingredients of plastics, but resins are the basic organic materials from which plastics are formed. Fillers, solvents, , stabilizers, and colorants influence many of the characteristics of plastics. A resin is the polymeric material that helps impart many of the physical characteristics of the solid plastics. It is the molecular arrangement of the resin that determines whether a plastics is thermosetting or thermoplastic. Thermoplastic materials increase in plasticity with temperature. They become soft when heated and solid when cooled to room temperature. One analogy is a dish of butter. When heated, the butter becomes soft; when cooled to room temperature, it solidifies. Thermoplastics are easily formed into useful products because weak forces allow slippage between the molecules. The molecules themselves are held by the stronger covalent bonds. There is a practical limit to the number of times a thermoplastic material may be formed because repeated processing may cause some of the additives to be lost.

8

PLASTIC TERMINOLOGY

ABRASION RESISTANCE COEFFICIENT OF LINEAR THERMAL EXPANSION Ability to withstand the effects of repeated wearing, rubbing, scrap­ The amount of growth which occurs in a material when it is heated ing, etc. from one ambient temperature to another ambient temperature and is normally expressed in terms of in./in./°F. ACETAL RESINS The molecular structure of the polymer is that of a linear acetal, COEFFICIENT OF FRICTION consisting of unbranched chains. The relation between force of frictional and normal pressure. Many factors affect friction & the lower the coefficient of friction, the lower ACIDS the wear on the machine or material. One of a class of substances compounded of hydrogen and one or more other elements, capable of uniting with a base to form a salt, and COLD FLOW in aqueous solution, turning blue litmus red. Change in dimensions or shape of some materials when subjected to external weight or pressure or pressure at room temperature. ACRYLATE RESINS A class of thermoplastic resins produced by polymerization of acrylic COMPOUND acid derivatives. A combination of ingredients before being processed or made into a finished product. Sometimes used as a synonym for material, ADHESIVE formulation. A substance capable of holding materials together by surface attachment. COMPRESSIVE STRENGTH The maximum load in lbs. which a 1" square section of material will AGING support without fracturing. The effect of time on plastics exposed indoors at ordinary conditions of temperature and relatively clean air. CONDENSATION A chemical reaction in which two or more molecules combine, usu­ ALKALIES ally with the separation of water or some other simple substance. Compounds capable of neutralizing acids and usually characterized by an acrid taste. Can be mild like baking soda or highly caustic like COPOLYMER lye. The product of simultaneous polymerization of two or more polymer­ izeable chemicals, commonly known as monomers. ANNEALING A process of holding a material at a temperature near, but below, its CRAZING melting point, the object being to permit stress relaxation without Fine cracks at or under the surface of a plastic. distortion of shape. CREEP ARC RESISTANCE The dimensional change with time of a material under load, following Time required for a given electrical current to render the surface of a the initial instantaneous elastic deformation. Creep at room tempera­ material conductive because of carbonization by the arc flame. ture is sometimes called Cold Flow. BLISTER CROSS LAMINATE Undesirable rounded elevation of the surface of a plastic, whose A laminate in which some of the layers of material are oriented boundaries may be either more or less sharply defined, somewhat approximately at right angles to the remaining layers with respect to resembling in shape a blister on the human skin. A blister may burst the grain or strongest direction in tension. and become flattened. CROSS-LINKING BOND Applied to polymer molecules, the setting-up of chemical links To attach by means of an adhesive. between the molecular chains. When extensive, as in most thermoset­ ting resins, cross-linking makes one infusible super-molecule of all BURNED the chains. Showing evidence of thermal decomposition through some discolor­ ation, distortion, or destruction of the surface of the plastic. DEFORMATION UNDER LOAD The percentage of deformation that will occur in a material under a BUTADIENE STYRENE-PLASTICS given period of time. A synthetic resin derived from the copolymerization of butadiene gas and styrene liquids. DEGRADATION A deleterious change in the chemical structure of a plastic. CALENDERING A process by which a heated rubber plastic product is squeezed DELAMINATION between heavy rollers into a thin sheet or film. The film may be The separation of the layers in a laminate caused by the failure of the frictioned into the interstices of cloth, or it may be coated onto cloth or adhesive. paper. DETERIORATION CAST RESIN A permanent change in the physical properties of a plastic evidenced A resinous product prepared by pouring liquid resins into a mold and by impairment of these properties. heat-treating the mass to harden it. DIELECTRIC CONSTANT CELLULOID Specific inductive capacity. The dielectric constant of a material is the A thermoplastic material made by the intimate blending of cellulose ratio of the capacitance of acondenser having that material as dielect­ nitrate with camphor. Alcohol is normally employed as a volatile ric to the capacity of the same condenser having a vacuum as solvent to assist plasticization, and is subsequently removed. dielectric. CELLULOSE DIELECTRIC LOSS A natural high polymeric carbohydrate found in most plants; the main The ease or difficulty with which the degree of dielectric constant constituent of dried woods, jute, flax, hemp, ramie, etc. Cotton is occurs. almost pure cellulose. DIELECTRIC STRENGTH CELLULOSE ACETATE Expressed in volts per mil and represents the number of volts required An acetic acid ester of cellulose. It is obtained by the action, under to cause an electrical breakthrough. rigidly controlled conditions, of acetic acid and acetic anhydride on purified cellulose usually obtained from cotton linters. All three avail­ DIFFUSION able hydroxyl groups in each glucose unit of the cellulose can be The migration or wandering of the particles or molecules of a body of acetylated but in the material normally used for plastics, it is usual to fluid matter away from the main body through a medium or into acetylate fully and then to lower the acetyl value (expressed as acetic another medium. acid) to 52-56% by partial hydrolysis. When compounded with suita­ DIMENSIONAL STABILITY ble plasticizers it gives a tough thermoplastic material. Ability of a plastic part to maintain its original proportions under CEMENT conditions of use. dispersion of "solution" of unvulcanized rubber or a plastic in a A DUROMETER volatile solvent. This meaning is peculiar to the plastics and rubber Trade name of the Shore Instrument Company for an instrument that industries and may or may not be an adhesive composition. measures hardness. The rubber or plastics durometerdeterminesthe

9

PLASTIC TERMINOLOGY

"hardness" of rubber or plastics by measuring the depth of penetra­ HOOP STRESS tion (without puncturing) of a blunt needle compressed on the sur­ The stress imposed on a cylindrical wall by internal pressure loading face for a short period of time. which acts so as to split the wall normal to any radius-wall intercept. ELASTIC LIMIT IMPACT STRENGTH The load at which a material will no longer return to its original form (1) The ability of a material to withstand shock loading; (2) the work when the load is released. done in fracturing, under shock loading, a specified test specimen in a specified manner. ELASTOMER A material which at room temperature stretches under low stress to at IMPERMEABILITY least twice its length and snaps back to the original length upon Permitting no passage into or through a material. release of stress. INJECTION MOLDING ELECTRICAL PROPERTIES A molding procedure whereby a heat-softened plastic material is Primarily the resistance of a plastic to the passage of electricity. forced from a cylinder into a relatively cool cavity which gives the article the desired shape. ELONGATION The ability of a material to increase in length expressed as a IZOD IMPACT TEST percentage. A test designed to determine the resistance of a plastics material to a shock loading. It involves the notching of a specimen, which is then EMULSION placed in the jaws of the machine and struck with a weighted pendu­ A dispersion of one liquid in another-possible only when they are lum. See also Impact Strength. mutually insoluble. LIGHT STABILITY ESTER Ability of a plastic to retain its original color and physical properties A compound formed by the elimination of waste during the reaction upon exposure to sun or artificial light. between an alcohol and an acid; many esters are liquids. They are frequently used as plasticizers in rubber and plastic compounds. LIGHT TRANSMISSION The amount of light that a plastic will pass. ETHYL CELLULOSE A thermoplastic material prepared by the ethylation of cellulose by LONGITUDINAL STRESS diethyl sulfate or ethyl halides and alkali. The stress imposed on the long axis of any shape. It can be either a compressive or tensile stress. EXTRUSION The compacting of a plastic material and forcing of it through an LOW PRESSURE LAMINATES orifice in more or less continuous fashion. In general, laminates molded and cured in the range of pressures from 400 p.s.i. down to and including pressures obtained by the mere FABRICATE contact of the plies. To work a material into a finished form by machining, forming, or other operation, orto make flexible film or sheeting into end-products LUBRICANT by sewing, cutting, sealing or other operation. A substance used to decrease the friction between solid faces, and sometimes used to improve processing characteristics of plastic compositions. A material added to a plastic composition to impart certain qualities in the finished article. MELAMINE PLASTICS Thermosetting plastics made from melamine and formaldehyde FLEXURAL STRENGTH resins. The ability of a material to deflect under load and return to its original condition expressed in lbs. per square inch. MELTING POINT The temperature at which solid and liquid forms of asubstance are in FLUOROCARBONS equilibrium. In common usage the melting point is taken as the The family of plastics including (PTFE), temperature at which the liquid first forms in a small sample as its polychlorotrifluoroethlylene (PCTFE), polyvinylidene and fluorinated temperature is increased gradually. ethylene propylene (FEP), q.v. They are characterized by properties including good thermal and chemical resistance and non­ MODULUS adhesiveness, and possess a low dissipation factor and low dielectric A term that may be applied to either tensile, flexural, compressive, or constant. Depending upon which of the fluorocarbons is used, they torsional actions. It defines the number of lbs. per square inch are available as molding materials, extrusion materials, dispersions, required to cause deformation, elongation, or flexure in a material. film or tape. MODOLUS OF ELASTICITY FORMULATION The ratio of stress to strain in a material that is elastically deformed. A combination of ingredients before being processed or made into a finished product. Sometimes used as a synonym for material, MOISTURE RESISTANCE compound. Ability to resist absorption of water. FUSE To join two plastic parts by softening the material by heat or solvents. The simplest repeating structural unit of a polymer; for addition polymers this represents the original unpolymerized compound. GENERIC Common names for types of plastic materials. They may be either NON-FLAMMABLE chemical terms or coined names. They contrast with trade marks Will not support combustion. which are the property of one company. NON-RIGID PLASTIC HARDNESS A plastic which has a stiffness or apparent modulus of elasticity of not A measure of the degree of surface hardness as measured on the over 10,000 psi at 23°C when determined in accordance with the Rockwell scale. Standard Method of Test for Stiffness in Flexure of Plastics. HEAT DISTORTION NON-TOXIC The temperature at which a material bends a given number of mils Non-poisonous. under a given load. Commonly used as a relative comparison of NOTCH SENSITIVITY materials. The extent to which the sensitivity of a material to fracture is increased HEAT RESISTANCE by the presence of a surface in homogeneity such as a notch, a The ability to withstand the effects of exposure to high temperature. sudden change in section, a crack or a scratch. Low notch sensitivity Care must be exercised in defining precisely what is meant when this is usually associated with ductile materials, and high notch sensitivity term is used. Descriptions pertaining to heat resistance properties with brittle materials. include: bailable, washable, cigarette-proof, sterilizable, etc.

10

TERMINOLOGY NYLON catalyst at relatively low pressures and temperatures. The generic name for all synthetic fiber-forming ; they can be formed into monofilaments and yarns characterized by great POLYSTYRENE toughness, strength and elasticity, high melting point, and good A water-white thermoplastic produced by the polymerization of sty­ resistance to water and chemicals. The material is widely used for rene(vinylbenezene). The electrical insulating properties of polysty­ bristles in industrial and domestic brushes, and for many textile rene are outstandingly good and the material is relatively unaffected applications. It is also used in injection molding gears, bearings, by moisture. In particular, the power loss factor is extremely low over combs, etc. the frequency range 10'-10/c.p.s. OLEFINS RESINS A group of unsaturated hydrocarbons of the general formula CnH2n, A family of resins produced by reacting diisocyanate with organic and named after the corresponding parafins by the addition of "ene" compounds containing two or more active hydrogens to form poly­ or "ylene" to the stern. Examples are ethylene and propylene. mers having free isocyanate groups. These groups, under the influ­ ence of heat or certain catalysts, will react with each other, or with ORANGE-PEEL water, glycols, etc., to form a thermosetting material. Uneven surface somewhat resembling an orange peel. POLYVINYL CHLORIDE (PVC) ORGANIC CHEMICAL A thermoplastic material composed of polymers of vinyl chloride, a Originally applied to chemicals derived from living organisms, as colorless solid with outstanding resistance to water, alcohols, and distinguished from "inorganic" chemicals found in minerals and inan­ concentrated acids and alkalies. It is obtainable in the form of gran­ imate substances; modern chemists define organic chemicals more ules, solutions, latices and pastes. Compounded with plasticizers, it exactly as those which contain the element carbon. yields a flexible material superior to rubber in aging properties. It is widely used for cable and wire coverings, in chemical plants, and in PHENOLIC RESIN the manufacturing of protective garments. A synthetic resin produced by the condensation of an aromatic alcohol with an aldehyde, particularly of phenol with formaldehyde. POROSITY Phenolic resins form the basis of thermosetting molding materials, Presence of numerous visible voids. laminated sheet, and stoving varnishes. They are also used as impregnating agents and as components of paints, varnishes, lac­ POSTCURE quers and adhesives. Those additional operations to which acured thermosetting plastic or rubber composition is subjected to enhance the level of one or more PLASTIC properties. (n.) One of many high-polymeric substances, including both natural and synthetic products, but excluding the rubbers. At some stage in RAYON its manufacture every plastic is capable of flowing, under heat and The generic term for fibers, staple, and continuous filament yarns pressure if necessary, into the desired final shape (adj.) Made of composed of regenerated cellulose, but also frequently used to des­ plastic; capable of flow under pressure or tensile stress. cribe fibers obtained from cellulose acetate or cellulose triacetate. Rayon fibers are similar in chemical structure to natural cellulose PLASTICITY fibers (e.g. cotton) except that the synthetic fiber contains shorter A property of plastics and resins which allows the materials to be polymer units. Most rayon is made by the viscose process. deformed continuously and permanently without rupture upon the application of a force that exceeds the yield value of the material. REINFORCED PLASTICS Plastics with high strength filler imbedded in the composition, result­ ing in some mechanical properties superior to those of the base resin. A liquid or solid incorporated in natural and synthetic resins and related substances to develop such properties as resiliency, elasticity, RESILIENCE and flexibility. Usually regarded as another name for elasticity. While both terms are fundamentally related, there is a distinction in meaning. Elasticity is a PLASTICS general term used to describe the property of recovering original Plastics based on polymers made with butene as essentially the sole shape after a deformation. Resilience refers more to the energy of monomer. recovery; that is, a body may be elastic but not highly resilient. POLYCARBONATE RESINS RESIN Polymers derived from the direct reaction between aromatic and Any of a class of solid or semisolid organic products of natural or aliphatic dihydroxy compounds with phosgene or by the ester ex­ synthetic origin, generally of high molecular weight with no definite change reaction with appropriate phosgene-derived precursors. melting point. Most resins are polymers, q.v. POLYESTER RIGID PLASTICS A resin formed by the reaction between a dibasic acid and dihydroxy For purposes of general classification, a plastic that has a modulus of alcohol, both organic. Modification with multi-functional acids and/or elasticity either in flexure or in tension greater than 100,000 p.s.i. at bases and some unsaturated reactants permit cross-linking to ther­ 23°C and 50% relative humidity when tested in accordance with mosetting resins. modified with fatty acids are called ASTM Methods D747 or D790 Test for Stiffness of Plastics. Alkyds. ROCKWELL HARDNESS POLYETHYLENE A common method of testing a plastics material for resistance to A thermoplastic material composed by polymers of ethylene. It is indentation in which a diamond or steel ball, under pressure, is used normally a translucent, tough, waxy solid which is unaffected by to pierce the test specimen. The load used is expressed in kilograms. water and by a large range of chemicals. RUBBER POLYMER An elastomer capable of rapid elastic recovery after being stretched A high-molecular-weight organic compound, natural or synthetic, to at least twice its length at temperatures from O to 150° F at any whose structure can be represented by a repeated small unit, the mer; humidity. Specifically, Hevea or natural rubber, the standard of com­ e.g., polyethylene, rubber, cellulose. Synthetic polymers and formed parison for elastomers. by addition or condensation polymerization of monomers. If two or more monomers are involved, a copolymer is obtained. Some poly­ SELF-EXTINGUISHING mers are elastomers, some plastics. A somewhat loosely-used term describing the ability of a material to cease burning once the source of flame has been removed. POLYMERIZATION Chemical change resulting in the formation of a new compound SEMIRIGID PLASTIC whose molecular weight is usually a multiple of that of the original For purposes of general classification,a plastic that has a modulus of substance. elasticity either in flexure or in tension between 10,000 and 100,000 p.s.i. at 23°C and 50% relative humidity when tested in accordance POLYOLEFIN with ASTM Method D747 or D790 Test for Stiffness of Plastics. A polymer prepared by the polymerization of an Olefin{s) as the sole Monomer(s). SHORE HARDNESS A method of determining the.hardness of a plastic material using a POLYPROPYLENE scelroscope. This device consists of a small conical hammer fitted A tough, lightweight rigid plastic made by the polymerization of with a diamond point and acting in a glass tube. The hammer is made high-purity propylene gas in the presence of an organometallic to strike the material under test and the degree of rebound is noted

11

PLASTIC TERMINOLOGY

on a graduated scale. Generally, the harder the material the greater THERMOSET will be the rebound. A material that will undergo or has undergone a chemical reaction by the action of heat, catalysts, ultra-violet light, etc., leading to a rela­ SIMULATED WEATHERING tively infusible state. Typical of the plastics in the thermo-setting The exposure of plastics to cyclic laboratory conditions of high and family are the aminos (melamine and urea), most polyesters, alkyds, low temperatures, high and low relative humidities, and ultraviolet epoxies and phenolics. radiant energy in an attempt to produce changes in their properties similar to those observed on long-time continuous exposure out­ TOLERANCE doors. The laboratory exposure conditions are usually intensified A specified allowance for deviations in weighing, measuring, etc., or beyond those encountered in actual outdoor exposure in an attempt for deviations from the standard dimensions or weight. to achieve an accelerated effect. TRANSLUCENT SIMULATED AGING Descriptive of a material or substance capable of transmitting some The exposure of plastics to cyclic laboratory conditions of high and light, but not clear enough to be seen through. low temperatures, and high and low relative humidities in an attempt to produce changes in their properties similar to those observed on TRANSPARENT long-time continuous exposure to conditions of temperature and Descriptive of a material or substance capable of a high degree of relative humidity commonly encountered in-doors or to obtain an light transmission, e.g., glass. Some polypropylene films and acrylic acceleration of the effects of ordinary indoor exposure. The labora­ moldings are outstanding in this respect. tory exposure conditions are usually intensified beyond those actu­ ULTRAVIOLET ally encountered in an attempt to achieve an accelerated effect. Zone of invisible radiations beyond the violet end of the spectrum of SOLVENT visible radiation. Since UV wavelengths are shorter than the visible, The medium within which a substance is dissolved; most commonly their photons have more energy, enough to initiate some chemical applied to liquids used to bring particular solids into solution, e.g. reactions and to degrade most plastics. acetone is a solvent for PVC. VACUUM FORMING SPECIFIC GRAVITY Method of sheet forming in which the plastic sheet is clamped in a The density (mass per unit volume) of any material divided by that of stationary frame, heated, and drawn down by a vacuum into a mold. water at a standard temperature, usually 4° C. Since water's density is In a loose sense, it is sometimes used to refer to all sheet forming nearly 1.00 g./cc., density in g./cc. and specific gravity are numerically techniques, including Drape Forming, q.v., involving the use of nearly equal. vacuum and stationary molds. SPECIFIC HEAT VINYL CHLORIDE PLASTICS Ratio of the thermal capacity of a substance to that of water at 15°C. Plastics based on resins made by the polymerization of vinyl chloride or copolymerization of vinyl chloride with minor amounts (not over 50 STRENGTH per cent) of other unsaturated compounds. The mechanical properties of a plastic, such as a load or weight­ carrying ability, and ability to withstand sharp blows. Strength proper­ VINYL PLASTICS ties include tensile, flexural, and tear strength, toughness, flexibility, Plastics based on resins made from vinyl monomers, except those etc. specifically covered by other classifications, such as acrylic and styrene plastics. Typical vinyl plastics arepolyvinyl chloride, polyvinyl STRESS-CRACK acetate, polyvinyl alcohol, and , and copolymers of External or internal cracks in a plastic caused by tensile stresses less vinyl monomers with unsaturated compounds. than that of its short-time mechanical strength. VIRGIN MATERIAL STRETCH FORMING A plastic material in the form of pellets, granules, powder, flock or A plastic sheet forming technique in which the heated thermoplastic liquid that has not been subjected to use or processing other than that sheet is stretched over a mold and subsequently cooled. required for its initial manufacture. TEAR STRENGTH VISCOSITY Resistance of a material to tearing (strength). Internal friction of a liquid because of its resistance to shear, agitation, or flow. TENSILE STRENGTH The capacity of a material to resist a force tending to stretch it. VOLUME RESISTIVITY Ordinarily the term is used to denote the force required to stretch a The ability of a material to impede the flow of electricity as expressed material to rupture, and is known variously as "breaking load", "break­ in ohms per centimeter. ing stress", "ultimate tensile strength", and sometimes erroneously as "breaking strain." In plastics testing, it is the load in pounds per square WATER ABSORPTION inch or kilos per square centimeter of original cross-sectional area, The percentages by weight of water absorbed by a sample immersed supported at the moment of rupture by a piece of test sampie on being in water. Dependent upon area exposed. elongated. WATER VAPOR TRANSMISSION THERMAL CONDUCTIVITY The penetration of a plastic by moisture in the air. Ability of a material to conduct heat; physical constant for quantity of heat that passes through unit cube of asubstance in unit of time when WEATHER RESISTANCE difference in temperatures of two faces is 1 Ability of a plastic to retain its original physical properties and °. appearance upon prolonged exposure to outdoor weather. THERMAL EXPANSION The increase in length of a dimension under influence of a change in WELDING temperature. Joining thermoplastic pieces by one of several heat-softening proc­ esses. In hot-gas welding, the material is heated by a jet of hot air or THERMOFORMING inert gas directed from a welding "torch" onto the area over condi­ Any process of forming thermoplastic sheet which consists of heating tions of time, temperature and pressure. the sheet and pulling it down onto a mold surface. YIELD POINT THERMOPLASTIC There are various types of yield points - compressive, tensile, flexu­ (adj.) Capable of being repeatedly softened by heat and hardened by ral, and torsional. The point at which a material under stress will no cooling. (n.) A material that will repeatedly soften when heated and longer return to its original dimensions after removal of the stress. harden when cooled. Typical of the thermoplastics family are the styrene polymers and copolymers, acrylics, cellulosics, polyethy­ YIELD STRESS lenes, vinyls, , and the various fluorocarbon materials. The force which must be applied to a plastic to initiate flow.

12

CNC Machining vs. Injection Molding High Performance Plastics Parts In reviewing applications for high­ ing and past curing of parts may performance thermoplastics, machin­ exceed the capabilities of injection ing may be the cost-effective alterna­ molding. tive to injection molding. Many high During the molding process, the flow performance plastics are being speci­ of the molten plastic sometimes caus­ fied today in very demanding metal­ es tolerance variations and dimension­ replacement applications. Some of the al instability. Machined parts from reasons for this include high continu­ stock shapes normally have more con­ ous-use temperatures, high strength­ sistent thermal expansion properties to-weight ratio, toughness, impact and and, therefore, are more dimensionally corrosion resistance, noise and vibra­ stable when exposed to elevated tem­ tion attenuation, and excellent electri­ peratures, cyclic loads, and harsh cal properties. Also, with the many chemical environments. Stock shapes types of base resins combined with are annealed after the converting the numerous filled and reinforced process, which relieves any residual grades, materials can be tailored to stress that may have been introduced. best suit application requirements. Subsequent further annealing may Once the material is selected, the also occur between machining process must be chosen. This is where processes and as a finished part - designers may find that machining of providing a virtual stress-free product. high-performance plastics, rather than Additionally, in some cases, the mater­ injection molding, can be a better ial selected may not be injection mold­ method of producing the parts. A able. broad range of high performance Surface markings associated with gat­ materials are available as stock ing, flashing, flow patterns, and weld shapes - rod, sheet, plate, tubular bar, lines created by the molding process profile, etc. If the material is not readily may also create design and structural available as a stock item, it possibly complications. Molded parts with thick can be specifically extruded. sections can also present problems. Machining is frequently chosen over Normally, walls need to be held to no molding because the quantities are not more than 1/ 4 11 thick. Thicker cross high enough to justify the capital sections results in shrinking, and con­ investment for an injection mold. sequently, sink marks. Mechanical slides, pins and other When large-cross-sectional or large­ hydraulic tooling features complicate diameter stock shapes are machined, the costs, lead time, and cycle time these problems do not exist. Adjacent associated with molding in features. Of thick and thin sections can be easily special note, today there is available combined and, in addition, taper or high-speed, precision, CNC equip­ angle is not required as in a ment especially designed for plastics. molded product for part removal from This maximizes efficiencies, reduces the tool. All surfaces can be complete­ costs, and minimizes lead time. Also ly flat on machined parts if desired. tolerances attainable through machin-

13

Advantages of Machining vs. Molding for High-Performance Materials 1 . Tooling costs are usually low 8. Part properties are more consis­ because expensive injection molds tent because there are no varia­ are not necessary. tions caused by melt flow. 2. With a few exceptions, closer tol­ 9. There are no nonparallel or erances are possible. crooked surfaces caused by mold 3. The size of a part can be altered at draft. a moment's notice, providing 10. There are no weld lines. greater design flexibility. 11. Cross sections greater than 1/4 4. There are no extensive delays for inch can be machined without sur­ "first parts." face marks and internal voids. 5. Parts with multiple undercuts or 12. Materials can be changed easily. adjacent heavy/thin sections that 13. Parts are uniform in crystalline are difficult to injection mold can structure and do not have a "skin" be successfully machined. problem. 6. There are no gate scars or gate areas with high stress. 7. The possibility of part distortion is lessened because rod and plate are stress-relieved prior to machin­ ing. Molded parts may distort if annealed.

14

THERMOFORMING - VACUUM FORMING The process of thermoforming involves large parts without expensive equipment the controlled heating of a thermoplastic and tooling; 2) the ease and ability of pro­ material to a temperature where its shape ducing large production quantities; 3) inex­ may be altered to the shape of a mold. This pensive mold and part design modifica­ physical change to pre-heated thermoplas­ tions; and 4) the ability to produce lami­ tic sheet is accomplished by vacuum, air nated or foam filled parts. pressure, or direct mechanical force. Once The thermoplastic materials most com­ the sheet assumes the desired shape of the monly specified are; Acrylic, ABS, PVC, mold design, it is allowed to cool on the C.A.B. and Polycarbonate. Additional mate­ mold. This curing process assures the rials are also available to accommodate shape of the finished product and allows specific design parameters such as fire the plastic material to retain its physical retardance, FDA approval, and U.V. sta­ characteristics. The finished part is then bility. removed from the mold to allow further fab­ The following charts detail the various rication and assembly. thermoforming techniques: The thermoforming process has several Please contact our office regarding your advantages: 1) the capability of forming specific design considerations. Thermoforming techniques

© Fig. 1: Straight vacuum forming. The plastic sheet is Thick areas clamped and heated. A vacuum beneath the sheet (A) then causes atmospheric pressure to push the sheet @ down into the mold. As the plastic contacts the mold (B), it cools. Areas of the sheet reaching the mold last are thinnest (C)

Fig. 2: Drape forming. The plastic sheet is clamped and Heater heated then drawn over the mold either by pulling it (A), 1 over the mold or by forcing the mold into the sheet. l i \ l \ l Ill l Id Vac. When the mold has been forced into the sheet and a seal 1 Thickest areas created (8). vacuum applied beneath the mold forces the sheet over the male mold. By draping the sheet over ®-l

Plastic sh •j Se © the mold, that part of the sheet touching the mold / Thin remains close to the original thickness of the sheet. Side eI Formed part areas walls are formed from the material draped between the ® - t r-ifYAr. top edges of the mold and the bottom seal area at the Vac. base. Final wall thickness distribution is shown in draw­

ing (C).

Fig. 3: Matched mold forming. Matched molds of wood, Ram metal, plasters, epoxy, etc., can be used to press the ! sheet to shape. The heated sheet may be clamped over ® the female (A) or can be draped over the mold force. tS---25 - tr As the mold closes it forms the sheet (B). Mold vents allow trapped air to escape. Clearance between the Male mold force and cavity of the mold depends upon toler­ form ances required in the part. Excellent reproduction of

mold detail and dimensional accuracy can be obtained © from matched mold forming, including lettering and Formed part grained surfaces. Material distribution of the formed part (C) will depend upon the shapes of the two forms Female

Fig. 4. Pressure bubble-plug assist vacuum forming. After the plastic sheet is heated and sealed across the female cavity (A), air is introduced into the mold cavity Pressure forming and blows the sheet upward into a bubble, stretching it evenly (B). Normally an electric photocell is used to ® ... a used) h n control height of bubble. A plug shaped roughly to the contour of the cavity plunges into the plastic sheet (C). When the plug has reached its lowest position a vacuum V1®:.. @ I '- is drawn on the cavity to complete formation of the sheet (D). In some instances pressure forming air is also used vacuum - in this process. Mold cavity

15

THERMOFORMING - VACUUM FORMING

fAir ® Fig. 5: Plug assist forming. After the heat-softened sheet is sealed across the mold cavity (A), a plug shaped ® similar to the cavity penetrates the sheet causing it to ,1 \', {seal stretch as it is carried into the cavity. When the plug has ; '., ', Air on t completed its penetration stroke (B), vacuum and/or [- -,Clamp compressed air is introduced to transfer the sheet from Heater ,:;,! \... the plug surface to the cavity mold surface (C). The plug D li''9' 5J.,.,3 (] size, combined with the rate and depth of penetration, affect the amount of stretching that occurs and is pri- Thick marily responsible for the ultimate material distribution in the finished product (D). Walls even Vent

Fig. 6: Vacuum snapback. After the plastic sheet is heated and sealed over the top of the female vacuum

(A), a vacuum applied at the bottom of the vacuum box pulls the plastic material into a concave shape. The © r ------, latter can becontrolled by turning vacuum on and off to Heater J maintain a constant shape in the sheet. When the plastic ',,,nm,1111(11\\111 Atmosphere r has been pre-stretched, the male plug enters the sheet WI\Ch (B) and a vacuum is drawn through the male plug. Clamp

Vacuum beneath the sheet is vented to the atmosphere 1 or light air pressure is applied in place of the vacuum. External deep draws (D) can be obtained from the -vac @ vacuum snapback process for forming items like lug­ gage, auto parts etc. \ Formed part

Fig. 7: Pressure bubble vacuum snapback. Once the heated plastic sheet is clamped and sealed across the pressure box (A), controlled air pressure applied under the sheet causes a large bubble to form. The sheet pre­ stretches about 35 to 40 percent. When it is preformed to the desired height (B) a plug is forced into it (C)while air .,2IT° pressure beneath the sheet remains constant. When the male plug closes on the pressure box, higher air pres­ ® ® sure beneath the sheet and vacuum behind the mold @Vac I.. creates a uniform draw. Air relief - Air Pressure box

Fig. 8: Trapped sheet, contact heat, pressure forming. Plastic sheet is inserted between the mold cavity and a hot blow plate. The plate (A), flat and porous, allows air to be blown through its face. The mold cavity seals sheet against the hot plate. Air pressure applied from the female mold beneath the sheet blows the sheet totally into contact with thehot plate. A vacuum (B) also can be drawn on the hot plate. After predetermined heating, plastic sheet is ready for forming. Applied air pressure through the hot plate forms the sheet into the female Steel knife can be mold. Venting (C) can be used on its opposite side. Steel used for seal and knives can be inserted in the molds for sealing. After subsequent trim 1f forming (D), additional closing pressure can beexerted. additional pressure can or be exerted at this stage atmosphere

Fig. 9. Air-slip forming. Technique is similar in many ways to snapback forming, but method of prebillow is different. Sheet is clamped to the top of a vertical walled chamber (A), and prebillow is achieved by a pressure buildup between the sheet and the mold table as the mold rises in the chamber (B and C). Mold table is gasketed at the edges to form a sliding seal against the chamber wall. Upon completion of stroke, the space between the mold andthe sheet is evacuated (D) and the t sheet is formed against the mold by differential air pressure.

Sealed air chamber

16

PRESSURE FORMING

Pressure forming is fast becoming a major part of the STRETCH RATIOS heavy gauge thermoforming industry and has become a viable molding alternative. The process is definitely not Since stretching is the prime and inherent problem in direct competition with or replacing high volume production forming plastic sheet, it behooves the designer to keep molding processes, but it is carving its own niche in the stretch ratios in mind. plastic molding industry. Obviously, the greater the stretch, the greater the Finally, the thermoformer can satisfy the industrial designer problems. Extreme stretching can result in unsatisfactory by giving them the sharp, crisp details, the tolerances and parts and a high scrap rate. finishes that they demand. Stretch ratio can be defined as the ratio of the area of the formed part to the net starting area of the material used. An average stretch ratio of 2 to 1 is normally quite What is Pressure Forming? conservative. A stretch ratio of 3 to 1 is about maximum for good design. Excess stretching can lead to rupture or Pressure Forming (PF) is a recent modification to a well inadequate strength. Note that we are talking of averages. known technology, vacuum forming. Localized areas might have twice this stretch, and depending on the application, can be quite satisfactory. A VACUUM FORMING PRESSURE FORMING designer would be advised to discuss this with a competent

HEATED THERMOPLASTIC SHEET PRESSURE LINE PRESSURE BOX thermoformer at the beginning of the project. / As an example, a hemisphere would have an average stretch ratio of 2 to 1 since the area of a hemisphere is twice the area of the blank from which it would be formed. Note, that if freeblown, the gauge could vary from the nominal thickness to approximately one third of the starting gauge.

ATMOSPHERIC PRESSURE A basic formula for determining average stretch ratios of rectangular parts is:

VACUUM VACUUM S = 1 + 2d(a+b) ab In vacuum forming a heated thermoplastic sheet is Where s = Average stretch ratio clamped in place above the surface of the mold. The air a = Length of formed part between the sheet and the mold is evacuated forming the b = Width of formed part 2 "vacuum" and atmospheric pressure (about 15 lb/in forces) d = Average depth the sheet into contact with the mold, where it cools, solidifies, and is removed. Thus, for a formed box with vertical side walls and the The same principle is employed in PF. The air between the following dimensions: mold and heated sheet is evacuated, but this time compressed air at up to 100 lb/in 2 is used to force the sheet a (length) = 12" into contact with the mold surface where it cools and b (width) = 12" solidifies. d (depth) = 6" There is a further difference between the two processes The stretch ratio would be: and this relates to the type of mold. In vacuum forming, both male and female molds are used; in PF, female molds S = 1 + 2(6") (12" + 12") are almost invariably used. (12" X 12") S = 1 + 288 MALE FORMING FEMALE FORMING 144

This may be expressed as a 3:1 stretch ratio. In this example, a .187" (3/16") thick starting gauge material would yield a part with an average wall thickness of .062" (1/16'.').

17

PRESSURE FORMING vs. VACUUM FORMING

The preceding principles hold whether the part is formed The basic purpose of higher pressure is to achieve a by vacuum forming or pressure forming. The difference in significant improvement in surface and mold detail. This is the two lies in the use of positive pressure instead of the particularly important where the desired material has a atmospheric pressure used when forming by vacuum. The relatively high hot strength (tensile strength at forming relative effective forming pressure used in pressure forming temperature). Figures #5 through #8 indicate some of the versus vacuum forming is frequently in the range of 10-to-1. situations where pressure forming has definite advantages; they represent parts currently being made from starting The following graph illustrates the sharper definition and sheet sizes ranging from one to twenty square feet in area. tighter corner radii achievable by pressure forming compared to vacuum forming: Figure #5 illustrates the poorly-defined corners and washed out appearance the inadequate pressure of vacuum forming often causes, in contrast to pressure-formed edges and corners (figure #5).

Figures #6 and #6A show the difference between vacuum Difference In Formed Radius forming and pressure forming of prisms in a lighting r ressure Forming vs Vacuum Formingr retractor. In this case, not only appearance, but function, is

affected, since a prism must have sharply-delineated edges 1

for good light refraction.

C:

0 Figures #7 and #7A again illustrate what can be expected

.175" if an undercut or reverse is formed into the part.

!l. Atmospheric pressure, which is all that is available with 0 C vacuum forming, simply is not strong enough to stretch

C: .1so· material with significant hot strength so it will conform to an ·0e LL VACUUM FORMING undercut of this type. :;;

.125" Figures #8 and #BA contrast the bridging effect caused by Cl C: inadequate pressure, with the sharp lines achieved through ·c ·.;

the flow of material under pressure. Tooling costs for .100"

a: pressure-formed parts are usually only a fraction of the

"il'l tooling costs for injection-molded parts with similar C: .075" ----t --- l--7' surfaces. :i : I-

- .050"----- I

.025" 1 --- +-I

-0- .050" .100" .150" .200" .250" .300"

Radius of Corner

18

PRESSURE FORMING vs. VACUUM FORMING

VACUUM FORMING PRESSURE FORMING

Figure #8 Figure #8A

19

PRESSURE FORMING

PF AND INJECTION MOLDING For corners it is advisable to have only two of the surfaces meeting at a tight radius. The third radius should be large-at For those familiar with injection molding process least four times the thickness of the original sheet if possible. capabilities, PF provides several advantages and disadvantages. Corners or edges meeting at angles significantly less than 90° should be avoided if possible, as they cause severe Taking the disadvantages first: thinning. • It is not possible to produce a part having a thickness GRAINS, TEXTURES, LETTERS AND LOGOS greater than the original sheet. Therefore, the provision of ribs, bosses etc. requires a further molding or PF will accurately reproduce mold textures and will fabricated detail attachments. produce a part having a uniform grain over all of its surface. We prefer to use machined aluminum tooling for grained • PF is a "one-sided" process. Changes in wall thickness parts (since it is less prone to voids) but cast tooling can will occur in the process, and these cannot be controlled also be used. as with "two-sided" injection molding. It should, of course, be remembered that graining is an • Holes, slits, apertures etc. cannot be molded in, but outside operation, performed after prototypes have been must be produced in a subsequent step. made to check dimensions. The advantages are: Tooling changes are fairly easy until the tool is grained­ • Because PF starts with sheet there are not the abrupt at which point they become impossible. Graining of course wall thickness changes associated with injection adds additional cost and lead time for tooling. molding; these wall thickness changes generate The following points should be kept in mind: differential cooling and produce sink marks. There are no sink marks with PF. • In order to get good detail, the heavier the initial sheet thickness, the heavier the grain should be. • Thermal stress concentrations are much lower in PF parts than in those produced by injection molding. There • The "valleys" of a grain must interconnect or air will be is thus a significantly reduced tendency to warp after trapped in the grain. Mold Tech grains are available upon demolding. This is due to a combination of factors: the request. homogeneous nature of the sheet material; the lower temperatures required for forming; and the use of "one • Draft angle must be increased to allow for release of the sided" tooling which allows shrinkage "away from" the molded part in grained tools. In principle, for a simple mold. box, it is allowable to have 0° draft. For a grained tool, unless the shrinkage is greater than the combined depth • Large parts are more easily formed with PF and are of the grain in opposite walls, a draft angle must be usually lighter. The only practical limitation on part size is allowed. This is normally 3° but it may be greater for that of the actual capacity of the PF machine - usually deep grains. 54"x90". • It is best to avoid texturing male protrusions into the There is no need for the provision of flow channels and mold, as "lock-up" in the grain may occur. increased wall thickness (hence higher weight), as there is when injection molding is used for large parts. • Holes, slots and other openings in an PF part are RAISED LETTERS AND LOGOS machined from formed homogeneous material in Raised letters and logos can also be either cut into the contrast to injection moldings where structural or mold or a separate die plate made for insertion in the mold. appearance defects can arise from discontinuities due to Again, the key problem is air release and each situation the divisions and reunion of the injected polymer melt. requires careful analysis. Excellent reproduction of lettering EDGES AND CORNERS and logos is, however, usually no problem. The basic rules on "two-surface" edges were covered earlier in some detail and the following summary should suffice: • The thinner the formed part wall thickness, the sharper can be the edge. • Optimum strength is provided when the inside part radius is 70-80% of the wall thickness and the outside part radius is 170-180% of wall thickness. • Edges and corners look "sharp" at radii below .030". • Corner radii down to 0.33 times wall thicknesses are possible, to a minimum wall thickness of roughly .050" - .060".

20

PRESSURE FORMING

DRAWINGS/DIMENSIONING PRACTICES Drawings should accurately define the form, fit, and function of the part; at the same time, bearing in mind the / limitations of the process. All dimensions should be given I I / from the tooled surface of the part. In most cases for I I Pressure Forming this will be the part exterior. In instances where male molds are used the dimensions should be given from the part interior. These tooled surfaces are repeatable and secondary fixturing is designed for location from these surfaces. In cases where specific surfaces opposite the tooled surface are critical to function, a secondary machining operation is necessary. The dimensions; however, should CUTOUT MOLDED IN, CUT OFF be stated from the tooled surface to the machined area. Radii and draft angles should be clearly defined from the

tooled surface as well. Draft angle notations may be made as follows: "Draft adds to dimension", "Draft decreases CUT OUTS, SLOTS AND HOLES dimension", or drawn draft angles to specific point of Routing, milling, or die punching can all be used to intersection. produce cut outs, slots and holes in finished parts. For The material starting gauge as well as minimum wall parts with multiple openings where an exact relationship is requirements should be noted. The material starting gauge required between a series of holes, die punching or the use is the sheet stock prior to the forming process. The of CNC milling or routing equipment is often preferable to minimum wall stock thickness is the thinnest wall section drilling. allowable at any wall cross section. An alternative method, which gives a better result in terms If sheet texture is to be used, the texture required (such as of strength and appearance, is to mold in protrusions and Haircell) and which side of the part to exhibit the grained channels (following the rules previously given) and to texture should be specified. remove the surplus material. For complicated arrangements of openings, this often yields considerable cost savings. If any painting to the exterior or RFI shielding to the interior are required, it should be noted as to any overspray requirements or selected areas where these coatings are TOLERANCES, WHAT'S EXPECTED/WHAT'S REQUIRED not required. Selectively designating areas not to receive coatings may impact tooling costs as well as part price and In industrial or heavy gauge thermoforming, holding should be as liberal as possible. tolerances is dependent upon many things, especially the skills of numerous craftsmen. These include pattern makers In order to minimize questions and delays, please contact making the master wood patterns, foundrymen pouring the us as early as possible in the design stage to answer any aluminum, toolmaker/finishers, jig and fixture builders, the dimensioning or tolerancing questions. leadman on a sheet extrusion line, forming machine operators, persons trimming and drilling and the person doing detail and deburring. Many times it is so easy when preparing detail drawings to simply carry out all dimensions to three places and put them down as such. In reality that may represent much closer tolerances than is needed and/or much closer than is practical with the process. When detailing the part, consider carefully which of your dimensions really do and do not need to be held close and dimension drawing accordingly. This step alone can many times save you a great deal of time, unnecessary cost and loss of integrity with your tooling and fabrications sources.

21

ABS ROYALITE® THERMOPLASTIC SHEET

S-250 is a medium impact ABS and suitable for general temperature durability. ABS/PVC sheet specifically developed to meet Federal Aviation and NFPA Code 56A specifications and combines good stiffness, applications. Its properties include good stiffness, tensile and Administration requirements. R 57 combines light weight with toughness and thermoformability with excellent electrostatic forming properties. Spectrum® S630 sheet is a medium density polyethylene very high impact strength, high tensile strength, and stiffness. discharge (ESD) protection. Available as roll stock in thicknesses product that combines the toughness of high density from 0.012" to 0.025" with a tolerance of ±0.002", ROYALSTAT'"M is a high impact ABS and suitable for general S-270 polyethylene with the flexibility of low density polyethylene. It is R 60 Fire-Rated Royalite® - R 60 is a rigid, fire-rated, R635 sheet assures excellent performance on in-line applications. Its properties include good impact tensile and suitable for , stitching and thermoforming applications. proprietary thermoplastic sheet specifically formulated to meet thermoformers and automatic chip placement systems. forming characteristics. the requirments of the FAR 25.853 A flammability test. R 60 Spectrum® S640 and S670 sheet are high density polyethelene combines very high impact strength and stiffness with excellent Royalstat™ R671 thermoplastic sheet is a unique conductive is a general purpose flame retardant ABS. Its properties products. 8640 is a high sag material formulated for deep draw S-510 formability in deep draws. R 60 has a high resistance to food and ABS product specifically formulated with extremely low chlorine include medium gloss surface, excellent impact strength, parts. S670 is a medium sag material formulated for small shallow environmental stains. levels. It meets the minimum static decay requirements outlined excellent formability and low temperature performance. S-510 draw parts common applications include material handling trays, in MIL-B-81705B and NFPA Code 56A specifications. Products has a flammability rating of UL94V-0 at .093 inch thickness. storage bins and tote . Royalstat® R63 R63 thermoplastic sheet is a conductive made from ROYALSTAT R671 sheet provide permanent ESD ABS/PVC product that is fire-rated*, and has a very high impact R 12 Rigid Royalite® - R 12 is a rigid ABS sheet with Spectrum® S690 sheet is a high molecular weight, high density protection and minimize the possibility of part failure due to strength, high tensile strength, excellent ductility, excellent contact corrosivity. It also provides the dimensional stability exceptionally good high temperature performance. R 12's heat polyethylene product that offers low sag during forming, making it formability and excellent low temperature performance. deflection temperature is 225°F as compared to 185°F for most ideal for large and shallow draw parts. required for today's automated manufacturing processes. ABS sheet products. Royalstat® R 64 thermoplastic sheet is a Conductive High ROYALSTAT R671 sheet combines good stiffness and toughness Royalite® DKE 400 thermoplastic sheet is a rigid, fire-rated* Density Polyethylene product. It combines high impact strength, with excellent thermoformability and electrostatic discharge (ESD) - R 20 is an all purpose grade that R 20 Rigid Royalite® acrylic/PVC product that combines very high impact strength, stiffness, chemical resistance, and good thermoformability. protection. combines a number of properties that make it ideal for the widest good abrasion resistance, stiffness and hardness with excellent range of applications. It has high impact strength, outstanding formability and exceptional chemical resistance. Royalstate® R 67 thermoplastic sheet is an ABS product that Royalite® R 84 Thermoplastic Sheet is a low-gloss, weather formability, and stiffness at high and low temperatures. provides permanent static protection and has high tensile resistant product. It offers very high impact strength and low Royalite® DKE 450 sheet is a rigid, fire-rated*, PVC/acrylic strength and good formability. It has a heat distortion temperature temperature performance, combined with excellent formability. R 21 Rigid Royalite® - R 21 is an economical rigid ABS that product that combines very high impact strength, stiffness and of 220°F. provides an ideal balance of properties not available in low cost hardness with excellent formability and exceptional chemical R 84/21 Royalite® - is a rigid ABS that provides an ideal ABS sheets. resistance. Royalstat® R 69 thermoplastic sheet is a Static Dissipative High balance of properties including high impact strength and low Density Polyethylene product. It combines high impact strength, temperature performance with excellent formability. - R 26 offers the user an unusual R 26 Rigid Royalite® R 59 Fire-Rated Royalite® - R 59 provides a unique ABS/PVC stiffness, chemical resistance, and good thermoformability. combination of very high tensile strength, impact strength, and sheet that meets industry flammability standards. It is recognized R 87/59 Weather-Resistant Fire-Rated Royalite® - R 87/59 stiffness combined with outstanding formability. The high under the component program of U.L., Inc., with a classification Royalstat™ R632 thermoplastic sheet from Royalite is a unique provides high weather resistance in an economical, fire-rated, hardness of R 26 makes it an excellent choice for luggage, food of 94 VE-1 at 0.062" gauge and 94 V-0 at 0.093" gauge. R 59 ABS/PVC material that is both electrically conductive and UL­ rigid, composite thermoplastic sheet. R 87/59 is suitable for trays, and formed boxes. combines very high impact strength with excellent ductability and listed. It meets minimum static decay requirements outlined in applications such as roof ventilators, marine applications and formability. R 59 also has excellent low temperature performance. MIL-B-81705B and NFPA Code 56A specifications. R632 sheet is recreational vehicle parts. Royalite® R77 is a rigid PVC product with excellent high gloss, recognized under the component program of Underwriters a material that is especially well suited for sanitary ware Royalite® R 60-LS (R61) thermoplastic sheet is a rigid, smoke Laboratories, Inc., with a classification of 94V-1 at 0.058", 94V-0 applications and indoor PVC applications. and fire-rated* acrylic/PVC product that combines high impact at 0.090", and 94-5VA at 0.090". Royalite® R77 is available on a non-cap sheet basis only. strength, abrasion resistance, stiffness and hardness with good formability and exceptional chemical resistance. Royalstat™ R635 thermoplastic sheet is a unique Spectrum® S370 sheet is a modified polypropylene product ABS/Polyolefin alloy that is electrically conductive. It meets the offering high temperature performance combined with cold R 57 Fire-Rated Royalite®- R 57 is a rigid, fire-rated minimum static decay requirements outlined in MIL-B-81705B

FIRE SPECIFICATION

FAR 25.853 (A) (B) Gauge Meeting Burn Test Product Material UL 94V-0 60 Sec. 12 Sec. Distinctive Feature 1. ROYALITE® DKE 400 PVC/Acrylic .028" No No Excellent Impact, Formability & Cleanability 2. ROYALITE® R 57 ABS/PVC .090" No Yes Excellent Formability 3. ROYALITE® R 59 ABS/PVC .085" No No Excellent Color & Gloss Control 4. ROYALITE® R 60 PVC/Acrylic .028" Yes Yes 5. ROYALITE® R 60-LS (R 61) PVC/Acrylic .031" Yes Yes Passes UMTA Specifications 6. ROYALITE® R 72 Modified PVC .031" Yes Yes Meets FAR 25.853 (a-1) 1988 Ver. 7. ROYALITE® R 721 Modified PVC .031" Yes Yes Meets FAR 25.853 (a-1) 1990 Ver. 8. SPECTRUM® DKE 450 PVC/Acrylic .060" No No Good Cleanability, HOT= 185 F Flow Characteristics 9. SPECTURM® S510 ABS/PVC .093" No No Medium Gloss 10. PREVEX® VF1 PEC .062" No No Heat Distortion = 185°F 11. NORYL® EN-185 PPO UL 94V-1 @ .120" No No Heat Distortion = 185°F

23

(ABS)

ACRYLONITRILE- BUTADIENE-STYRENE Introduced commercially in the 1940s, ABS is a terpolymer whose SUGGESTED APPLICATIONS sales have grown over the years to become the largest engineering thermoplastic in the world. In the U.S. alone, sales in ■ Aircraft interior trim 1990 exceeded 1.2 billion pounds. ABS enjoys a unique position KEY PROPERTIES ■ Cassette holders as a "bridge" between and higher-performing engineering thermoplastics. ■ Toughness ■ Business machine housings and parts ■ Stiffness ■ T ote bins and trays Chemistry and properties ■ Luggage The versatility of ABS is derived from its three monomeric building ■ Formability blocks - acrylonitrile, butadiene, and styrene. Each component ■ General Purpose Material At A Low Cost ■ Model building imparts a different set of useful properties to the final polymer. ■ Water purification equipment components Acrylonitrile primarily offers chemical resistance and heat stability; ■ Good Impact Strength butadiene delivers toughness and impact strength; and the ■ Excellent Aesthetic Qualities ■ Automotive parts styrene component provides ABS with rigidity and processability. ■ Laboratory equipment .., .,, Product No. S-250 S-270 S-510 R12 R20 R21 R26 R77 S370 S630 S640 S670 S690 DKE400 DKE450 R59 R60-LS R57 R60 R63 R64 R67 R69 R632 R635 R671 R84 R84/21 R87/59 Polymer ABS ABS ABS ABS PVC TPO MOPE HOPE HOPE HOPE PVC/ PVC/ ABS/PVC (R61) ABS/PVC PVC/ ABS/PVC HOPE ABS HOPE ABS/PVC ABS/POL YOLEFIN ABS/CONDUCTIVE PROPRI- PROPRI­ PVC/ABS ACRYLIC ACRYLIC PVC/ ACRYLIC ETARY ETARY Properties ACRYLIC

Foam Core Yes Yes

Flammability Ratings•

per Test Method: MVSS 302 Passes Passes Passes Passes Passes Passes Passes Passes Passes Passes Passes Passes Passes Passes Passes Passes Passes Passes Passes

UL94V-O Passes Listed Listed Listed Passes Passes Passes Passes Listed Listed

UL94-5V Listed Listed Listed

FAR 25.8538 Passes Passes

FAR 25.853A Passes

OSU Heat Release

Smoke Rating• UMTNDOT/FAA Passes

Static Conductive Yes Yes Yes Yes Yes Yes

Static Dissipative Yes

Pressure Formable Yes Yes Yes RATING Weather Resistance Low Low Low Low Low Low Low Low Average Low Low Low Low Good Good Low Good Low Good Low Low Low Low Very High Very High High Tensile Strength High High High Very High Good High Very High Very High Low Average Average Average Average Very High Very High High High High High High Good Good Good High Average High High High Average Stiffness High High High Very High High High Very High Very High Average Average Average Average Average Very High Very High High Very High High Very High High Average High Average High High High Impact Strength Very High Good High High Very High Very High Very High Very High Very High Very High Very High Very High Very High Very High Very High Very High Very High Very High Very High High Very High Average Very High High Average Average Very High Very High Very High Hardness High High High Very High Average High Very High Very High Low Low Low Low Low Very High Very High High Very High High Very High High Low High Low High High High High Temperature Performance High High Average Very High High High High Average Average Average Average Average Average Average Average Average Average Average Average Average Average Very High Average Average Average Average High High Average Low Temperature Performance High Average Average Average High High Average Average High High High High Very High Average Average Average Average Average Average Average Average Average Average Average Low Low Very High Very High Average Formability Excellent Excellent Excellent Excellent Excellent Excellent Excellent Good Good Average Average Average Good Very Good Excellent Excellent Good Excellent Very Good Good Good Good Good Average Good High Excellent Excellent Good Sag High Medium Low PHYSICAL PROPERTIES

Specific Gravityt 1.05 1.07 1.20 1.05 1.05 1.05 1.05 1.35 0.92 0.93 0.96 0.96 0.97 1.33 1.26 1.18 1.36 1.18 1.33 1.22 1.04 1.28 1.09 1.07 1.05 1.23 1.06 0.96 1.03 Tensile Strength, machine dir. (psi) 5000 4800 5500 6000 4600 5000 5500 6000 2400 2970 4000 4000 3100 6000 6800 4700 5500 5500 5500 5000 3950 4000 4100 4500 2200 4000 5200 4800 3500 Flexural Strength @ 72°F (psi) 7200 7500 10,500 9000 6500 8300 9000 10000 2700 3900 3800 5500 3500 9200 11,000 7700 9500 7500 10000 5700 3200 6500 3300 7000 3200 6600 8000 9000 7000 Flexural Modulus @ 72°F (10' psi) 280,000 240,000 340,000 3.0 2.3 2.7 3.0 3.4 1.0 1.4 1.7 2.0 1.4 3.2 3.8 2.7 3.4 2.5 3.0 2.1 1.9 2.5 2.2 2.9 1.3 2.4 3.1 3.0 2.4 Impact. Notched lzod.. @-72°F (ft.-lb./in. notch) 4.5 6.5 11 5.0 10.0 7.0 7.0 10.0 10.0 10.0 14.0 13.0 14.0 12.0 7.0 12.0 6.5 12.0 3.0 12.0 8.0 6.0

@-20°F (ft.-lb./in. notch) 4.0 2.5 3.0 1.0 8.0 10.0 1.0 1.0 1.8 1.6 1.5 2.0 2.5 8.0 1.0 1.0 4.0 3.0

Impact Strength, Gardner Drop Weight'·

Minimum Value (in.lb.) 125 250 200 200 160 280 300 300 300 240 240 120 200 120 240 160 320 120 320 280 280 120

Hardness, Rockwell R 103 86 96 103 110 98(2) 60(1) 65(1) 65(1) 60(1) 100 110 95 102 94 100 98 70(1) 98 70(1) 90 83 80 90 90 96 Compressive Strength (psi) Heat Deflection Temperature-Annealed.. @264 psi fiber stress (°F) 198° 195° 162 220 200 203 205 160 160 185 175 155 175 160 174 200 155 140 178 205 200 175

@66 psi fiber stress {°F) 180 150 170 180 170 170 190 190 156 220 135

Surface Resistivity (Ohm/square)• .. <10' <10' <10' <10' <10' <10' <10' Volume Resistivity (Ohm-cm)' .. <5x10' <10' <10' <10'

tUnpigmented. NOTE: These data are typical sheet properties and are not to be used for establishing minimum material specifications. They are the latest available at time of p(1) Shore D (2) Shore A (3) UL94V-1 publication and are authentic to the best knowledge of the company. The properties are listed solely to give general guidance and are not to be construed as •This term and any corresponding data refer to typical performance in the specific tests indicated and should not be construed to a warranty of any type. Please contact Toyalite for specific data to meet your design criteria. **© .125" thick. ***Thermoformed Sheet imply this material's behavior under actual fire and/or smoke conditions.

24

ACETRON® GP ACETAL

Acetron® GP is a general purpose acetal and Typical Applications Tubular Bar is the only porosity-free acetal product avail­ • Bearings 0.0.: 2" to 14" able today. Investments in process technolo­ • Gears 1.D.:1"to11" gy now provide the performance and • Electrical components Standard length: 13" machinability of acetal without center core • Bushings • Valve seats Strip porosity. An in-line photometric quality proce­ Thickness: .01O" to .125" • Thrust washers dure assures every plate and rod is porosity­ Width: ¼" to 24" • Rollers free as measured by quick check dye • Insulators Tubing penetrant test. • Sleeves O.D.: .064" to .500" Acetron® GP provides a high modulus of elas­ Key Benefits I.D.: Designed for individual application ticity coupled with great strength, stiffness • No centerline porosity and toughness. It is also characterized by a • High modulus of elasticity Type EN Rod low coefficient of friction and good bearing • High strength, stiffness (continued coiled rod) characteristics. • Low coefficient of friction Acetal can be supplied in • Good abrasion and impact continuous lengths of small Becasue acetal absorbs only minimal resistance diameter rod in coil form amounts of moisture, its physical properties • Low moisture absorption for high volume usage. remain constant in a variety of environments. • FDA and USDA compliant This product can be cus­ In high moisture situations, including sub­ tomer quoted in diameters merged applications, Acetron® GP bearings Availabilities up to¼". outperform nylon 4 to 1. Rod Diameter: Diameter: ¼2" to 6" .062", .093", .125", .138", Acetron® GP is ideally suited for mechanical Length: parts and electrical insulators which require .154", .187", .250" and To 2¾" diameter- intermediate diameters exceptional strength at above-normal temper­ 8 ft. nominal ature or moisture levels. Low moisture Over 2¾" diameter - FDA Compliant absorption gives excellent dimensional stabili­ 4 ft. nominal Colored Acetal ty to close-tolerance fabricated parts. Most Hex Rod Rod acetal formulations are FDA and USDA com­ 1/ie" increments from ¾e" to Diameter: pliant for applications involving contact with %" plus¾", ¼", 1" Available up to 6" food. Length: 6-8 ft. nominal Plate Thickness: Available up to 3: Acetal in FDA Compliant Colors Square Rod Acetron® GP is available in FDA compliant ¼" increments from ¼" to 1" Other shapes are available upon request. colors for a variety of medical, food contact, plus ¾e", ¾e" Length: 6-8 ft. nominal and decorative applications. Standard colors available include dark blue, dark green, grey, Plate brown, black, white, rust, light blue, light Thickness: ¼2" to 3" green, yellow and red. Width: 24" Length: 48" standard, Glass-reinforced Acetal available to 144" Information on glass-reinforced acetal is also Rectangular Bar available. Thickness: 1/ie" to 3" Width: 1" to 1O" Bushing Stock Nominal 0.0.: ¼" increments from ½" to 3" plus%",¼" Nominal 1.0.: ¼" increments from ½" to 1½" plus¾", %"

25

ACETRQN® GP ACETAL-PropertiesofAcetron®GPAcetal

Test Method Acetron® GP Property Units ASTM & Delrin* Acetal Product Extruded, unfilled Description

Mechanical 1 Specific Gravity - D792 1.41-1.42 2 Tensile Strength, 73°F psi D638 8,800-12,000 3 Tensile Modulus of Elasticitv, 73°F Psi D638 410,000-520,000 4 Elonaation, 73°F % D638 30-65 5 Flexural Strength, 73°F psi D790 13,000-15,500 6 Flexural Modulus of Elasticity, 73°F psi D790 375,000-550,000 7 Shear Strenath, 73°F Psi D732 7,700-9,500 8 Compressive Strength, 10% Def. psi D695 16,000-18,000 9 Compressive Modulus of Elasticity, 73°F psi D695 10 Coefficient of Friction (Dry vs. Steel) Dynamic® - - 25 11 Hardness, Rockwell, 73°F D785 R119-122 12 Durometer, 73°F - D2240 - 13 Tensile Impact ft. lb.fin. D1822 40-90 Thermal 14 Coefficient of Linear Thermal Expansion in./in.fF D696 6.7 X 1Q·5 15 Deformation Under Load (122°F, 2,000 psi) % D621 0.3-1.0 16 Deflection Temperature 264 psi °F D648 230-265 17 Ta-Glass transition (amorphous) °F - - 18 Melting Point (crystalline) OF D789 329-347 19 Continuous Service Temperature in Air (Max.) OF - 180

Electrical 20 Dielectric Strength Short Time Volts/ mil D149 380-500@ 15 21 Volume Resistivity OHM-Cm D257 1 X 1014-1 X 10 22 Dielectric Constant, 60Hz - D150 3.7 23 103Hz - D150 3.7 24 106Hz - D150 3.7 25 Dissipation Factor, 60Hz - - 26 10Hz -

Chemical 27 Water Absorption Immersion 24 Hours % D570@ 0.12-0.25 28 Saturation % D570 0.80-0.90 29 Acids, Weak, 73°F A 30 Strong, 73°F u 31 Alkalies, Weak, 73°F A 32 Strano, 73°F u 33 Hydrocarbons-Aromatic, 73°F A 34 Hydrocarbons-Aliphatic, 73°F A 35 Ketones, 73°F A 36 Ethers, 73°F A 37 Esters, 73°F A 38 Alcohols, 73°F A 39 lnoraanic Salt Solutions, 73°F - 40 Continuous Sunlight, 73°F -

26

ACETRON® NS ACETAL

NEW ACETAL-BASED COMPOUND WITH SOLID LUBRICANTS PROVIDES OUTSTANDING PERFORMANCE IN BEARING AND WEAR APPLICATIONS

Acetron is a new, patented, acetal-based compound containing special solid lubricants which provide superior performance in bearing and wear applications. These special lubricants are uniformly dispersed in the base acetal, providing a premium, internally-lubricated compound with high PV capabilities, low coefficient of friction, and an extremely good "k" factor. The solid lubricants, firmly locked in the acetal matrix, are always exposed to the bearing surface. This constant source of lubrication results in Acetron acetal's outstanding bearing performance compared to other bearing materials. The additives system which provides the lubrication is a patented composite. The system provides for lubrication aid during break-in of a bearing material and long-term lubrication for wear resistance. The acetal and solid lubricants do not absorb significant quantities of moisture making acetron acetal very stable in both wet and dry environments. It is recommended for precision, close tolerance parts. Acetron acetal should be considered for applications now serviced by other, more expensive, premium-priced, internally­ lubricated acetal compositions. This very competitively-priced product will out-perform other filled acetals in most bearing and wear applications.

PROPERTIES TYPICAL APPLICATIONS • High wear and abrasion resistance • Bearings • Low coefficient of friction • Bushings • Resilience and impact resistance • Valve seats • Non-abrasive to other materials • Thrust washers • Noise dampening characteristics • Seals • Low moisture absorption • Wear surfaces • Resistant to many chemicals • Rollers • Able to operate without lubrication • Guides • Low stick slip • Gears • Insulators

• Cams and cam followers • Sleeves

• Liners • Tooling fixtures • Forming dies

AVAILABILITIES Rod

Diameter: 1/4"' 5/15"' 3/a"' 7/15"' 1/2"' 9/15"' 5/a"' 3/4"' 7/s"' 1 "' 11//' 13/s", 11/2"'

15/8", 13//, 2", 21/2", 3", 4", 5", 6" Length: To 2%" diameter - 8'

Over 2%" diameter-4' Wear Rate, Coefficient of Friction and Limiting PV Data* Comparative Plate Wear Factor Wear Rate to Coefficient of Friction Limiting Acetal "K" Acetron2 NS Static (2) Dynamic (3) PV (4)

Acetron® NS 47 1.0 .13-.19 .15-.19 9,375 Size: 24" x 48" Delrin AF (a) 65 1.4 .13-.14 .15-.16 11,500 Tubular Bar Delrin 500CL (a) 176 3.7 .12-.14 .20-.21 3,500 Acetron" GP 200 4.3 .12-.28 .15-.35 2,700 Quoted on request Acetal 200 4.3 .12-.28 .15-.35 2,700 Turcite(b) 251 5.3 .13-.17 .17-.18 6,500

Acetrons NS has the lowest "K" factor of any acetal available today. It outperforms other acetals by up to 500%!

27

ACETRON® NS ACETAL

PROPERTIES of ACETRON® ACETAL

Test Typical Mechanical Method Unit Value Tensile strength, 73°F 0638 psi 7,500-8,000 Elongation (Ultimate) 73°F 0638 % 10-30 Modulus of Elasticity, 73°F 0638 psi 355,000 Tensile Strength, 158°F 0638 psi 5,500-6,000 Elongation (Ultimate) 158°F 0638 % 20-30 Tensile Impact Str., 73°F 01822 ft. lbs./in2 30-40 lzod Impact, 73°F 0256 ft. lb.fin. 1.2-1.4 lzod Impact, -40°F 0256 ft. lb.fin. .6-.8 Hardness, Rockwell 0758 - R116 Flexural Strength 0790 psi 6,500-7,000 Flexural Modulus 0790 psi 380,000-410,000 Deformation Under Load 0631 % .6-.7 Compressive Strength 1% Def. 0695 psi 7,000 Compressive Strength 10% Def. 0695 psi 14,000-15,000 Compressive Modulus 0695 psi 315,000 Shear Strength 0732 psi 6,000 Specific Gravity 0792 - 1.44 Moisture Absorption 24 HR 0570 % .14-.21 Moisture Absorotion Saturation 0570 % 1.9-2.1 Thermal Deflection Temp., 66 psi 0648 OF 325 Deflection Temp., 264 psi 0648 OF 270 Coefficient Thermal Expansion 0696 in./in./°F 4.7-5.0 X 1Q·5 Intermittent Use Temp. OF 250 Continuous Use Temp. OF 180 Melt Pt. 02133 OF 341-363 Flammability 0635 Slow Burninq Electrical Dielectric Strength S.T. 0149 Volts/Mil 325 Slidina Motion Bearina Coefficient of Friction Static1l1 .13-.19 (Against Polished Metal) Dynamic (2) .15-.19 PV Value (Unlubricated) To 200 ft./min. lb. • ft. 2 in • min. 8,750-10,000 Maximum Bearing psi 2,000 Maximum Surface Velocity fpm 400 3 "K" Wear Factor (3) in • min./ft. • lb. • hr. 44-50

Note: Property values are typical and should be used only as a guide to selection of materials and not as purchase specifications.

1 (1) Measured on thrust washer bearing under a (3) Measured on /2" 1.0. journal bearings at 5,000 PV (118 normal load of 50 lbs. Gradually increasing fpm & 42.4 psi). torque was applied until the bearing com­ K = h/PVT x 10 10 (cu. in. min./ft. lb. hr.) pleted a 90° rotation in about one second. where, h = radial wear, (in.) (2) Measured on thrust washer testing machine, P = normal pressure, (psi) unlubricated @ 20 fpm and 250 psi. V = sliding speed, (fpm) T = test duration, (hrs.)

28

ACRYLIC

Applications-Transparent aircraft or automotive reduce resistance to weathering. Affected by oxidizing enclosures, radio and television parts, lighting and acids, ketones, esters, aromatics and chlorinated drafting equipment, reflectors, control panels, hydrocarbons. , dial gauge lenses, light diffusers, optical systems, spectacles, study models, architectural Modified Acrylic-An addition to the acrylics family has panelling, outdoor signs and displays, reflectors. been a grade of material known as "impact acrylics." It is characterized by superior toughness and impact Characteristics-Thermoplastic, crystal clear, light in resistance, good dimensional stability, freedom from weight, reasonably tough, durable, flexible in thin deterioration to aging, low water absorption, resistance sections, transmits light around corners, low water to attack from most common chemicals, good electrical vapor diffusion constant, resistant to the effects of light, properties, and excellent stain resistance. oxygen, water and their composite action during In addition to its excellent flextural strength and weathering. Cast sheets noted for high degree of ultra toughness, it can be nailed or cemented. Superior violet transmission. Can be made to absorb ultra violet rigidity, freedom from odor, and light weight are other by special compounding. important advantages. The table below gives a more specific breakdown of properties. Basically, the impacts Advantages-High index of refraction, good are prepared by copolymerizing such monomers as weathering and aging properties, high transparency. acrylonitrile, butadiene, or styrene with the acrylic Good combination flexibility with shatter resistance, low monomers. Impact acrylics are used in molding water absorption and high degree of physical stability housings, piano and organ keys, marine hardware, etc. when in contact with water. Will not support fungal A high heat-resistant acrylic (with resistance to growth and immune to attack by such organisms. deformation under heat at least 35°F. better than most Resistant to most mineral acids, alkalies and standard grades) has been introduced based on hydrocarbons. compolymerizing alpha-methyl styrene with the acrylic Disadvantages-Tendency to cold flow, low softening monomer. point, (140 to 180 F.), low scratch resistance, stresses

Physical Properties of Acrylic GP' PROPERTY ASTM METHOD UNITS Average Value For .250" Thickness MECHANICAL Specific Gravity D792-66 1.19 Tensile Strength D638-72 (Rupture) psi 10,000 Elongation, Rupture % 4.2 Modulus of Elasticity psi 400,000 Flexural Strength D790-71 (Rupture) Method 1 psi 16,500 Modulus of Elasticity psi 475,000 Compressive Strength D695-69 (Yield) psi 18,000 Modulus of Elasticity psi 430,000 Compressive Deformation Under Load D621-64 2000 psi, 122°F, 24 hr. % 0.23 4000 psi, 122°F, 24 hr. % 0.81 Shear Strength D732-46 (1961) psi 9,000 Impact Strength lzod Milled Notch D256-73 ft. lbs.fin. of notch 0.4 Rockwell Hardness D785-65 M94 Barcol Hardness D2583-67 49 Residual Shrinkage' (Internal Strain) D702-68 Acrylic GP % approx. 2 OPTICAL Based on Clear Material Refractive Index D542-50 (1965) 1.49 Luminous Transmittance D1003-61 AS Cast Parallel % 91 Total % 92 Haze % less than 1 Luminous Transmittance D1003-61 After 1000 hrs. Accelerated D1499-64 Weathering - Parallel % 91 Effect of Accelerated Weathering D1499-64 on Appearance No Crazing, Discoloration or Warping Ultraviolet Transmission Cary @320m Model 11 % 0 Displacement Factor D637-50 (1965) 50 Sizes Tube Rod Cast Acrylic Tube Clear Cast Acrylic Rod Nominal OD Diameter

11;2 "x 12" 1// - 3" Standard Lengths 60" Clear Extruded Tube Clear Extruded Rod Outside Diam. Inside Diam. Diameter 1 1// -3" 1/8" - 23// /15" - 1 1 /2" Standard Lengths 6 ft. Standard Lengths 6 ft. Acrylic Sheets Thickness Size 1 1 / 16" - 4 // 48" X 72", 48" X 96" 60" X 96", 72" X 96"

29

(CAB) CELLULOSE ACETATE BUTYRATE

Cellulose Acetate Butyrate (CAB-UVEX®) • Gasoline Pump Faces is manufactured by the chemical modifica­ • Retail Displays tion of cellulose, a naturally occurring poly­ • Gauge Covers mer derived from wood pulp. The cellulose • Housings is modified by adding acetate and butyrate Properties - Features to form a transparent thermoplastic. Transparency. An excellent thermoplas­ Cellulose Acetate Butyrate possesses ex­ tic for multi-duty applications where clarity cellent impact strength, even at low tem­ and impact strength are required. peratures. This property is also combined Weather Resistance. This UV inhibiting with other outstanding characteristics such cellulosic is frequently used in the produc­ as transparency, colorability and durability. tion of outdoor sign faces where high Stock Sizes impact is required. .015" - .030" 21" X 51", Formability. The ease with which CAB .060" - .250" 48" X 96", 48" X 72" may be thermoformed allows for high cy­ Tubing cling production on semi-automatic and 1/8" O.D. - 8" automatic vacuum formers. 1/16", 1/8" I.D. increments Impact Strength. The excellent impact Standard Length: 6 & 12 ft. strength of this material has allowed it to Applications replace expensive metal machine guards. • Machine Guards Sound Barrier. This material offers excel­ • Line Covers lent dampening characteristics to meet • Skylights O.S.H.A. noise requirements.

ASTM Mechanical Properties Units and Conditions Test Method Value Hardness, Rockwell R scale D-785 88 ft.lb.Iin. 3.6 Notched cm.kgf/cm 20 Impact Strength, Charpy ft.lb.fin. No break Unnotched cm.kgf/cm D-256 No break @73°F ft.lb.fin. of notch 4.2 (23°C) cm.kgf/cm of notch 23 Impact Strength, lzod @-40°F ft.lb.fin. of notch 1.6 (-40°C) cm.kgf/cm of notch 8.7 psi 200,000 Modulus of Elasticity in Flexure D-790 kgf/cm 2 14,000 Tensile Properties Tensile Strength at Fracture psi 5,700 kgf/cm 2 400 Tensile Strength at Yield psi D-638 4,400 kgf/ cm 2 310 ElonQation at F.racture % 90 Thermal Properties @ 264 psi (18.6 kgf/cm 2) OF 152 - fiber stress 67 Deflection Temperature oc D-648 2 OF @ 66 psi (4.6 kgf/cm ) - 176 fiber stress oc 80 Softening Point, Vicat oc D-1525 96 8 X 1Q-5 in./in./° F Thermal Expansion D-696 cm/cm/°C 14 X 1Q-5 Permanence Properties Water Absorption %, 24 hour immersion at 122° F (50° C) 1.6 D-570 Soluble Matter Lost %, 24 hour immersion at 122° F (50° C) 0.1 Weight Loss on Heating %, 72 hours at 180° F (82° C) D-707 0.7 Miscellaneous Properties Specific Gravity D-792 1.20

30

CELCON® ACETAL COPOLYMER Table 1-2 - Typical Thermal Properties

ASTM Test Property Method Units M Series GC-25A

T hermal Deflection and Deformation Deflection Temperature D648 @ 264 psi Of 230 322 @ 66 psi Of 316 Deformation under load (2000 psi @ 122° F) D621 % 1.0 0.6 Miscellaneous Thermal Conductivity - BTU/hr./ft.2/° Flin. 1.6 - Specific Heat - BTU/lb./°F 0.35 - Coefficient of Linear Thermal Expansion D696 in./in./° F (Range: -30°C to +30°C} Flow direction 4.7x10-5 2.2x 10-5

Traverse direction 4.7x1Q-s 4.1x10·5

Flammability D635 in./min. 1.1 -

Table 1-3 - Typical Electrical Properties (fig. 1-1) FLEXURAL CREEP OF CELCON ACETAL COPOLYMER CELCON M90 2 M25, M90, M270, GC-25A at 73°F (23°C), 50% R.H. 500 psi FIBER STRESS (351,500 Kg / m )

ASTM Value Property Method Units M Series GC-25A 150, ---,---,-...,-----r--r------'I I /' 6 I ; / :,,,,,,,,,.2 Years :. ..- 3 Years Months: Year • / 1 Dielectric Constant 120 'it.• FLEXURAL CREEP (0.040" sheet) D150 I "': / I SPECIMEN SIZE 12.7cmxl.3cmx.3cm 102 Hz 3.7 4.12 y .. 3 10 Hz 3.7 4.10 :!2 I /:

4 10 Hz 3.7 4.08 ;i 90 I I/ /\ : p 106 Hz 3.7 4.04 0 V M90 a 240°F (ll6°C) i = u ', Dissipation (Power) uJ / / I I J.- 1 ...J 6 Factor D150 LL uJ II I -- I ' (0.040" sheet) 0 / --:-- -- I t 102 Hz 0.0010 0.0030 _;..-, , ; M9o a 1so°F cs2°cJ 3 30 .,_/: I • I 10 Hz 0.0010 0.0024 , / M90 73°F (23°C) : 1 a 4 10 Hz 0.0015 0.0026 J< I I 10 6Hz 0.0060 0.0070 - I --+------Surface Resistivity 0 -----' ------'-_._I _. , _, 0 8.000 16,000 24,000 32,000 (¼" Thick) D257 ohm 1.3x10' 6 2x10'6 TIME, HOURS Volume Resistivity (1/a" Thick) D257 ohm-cm 1x10'4 0.8x1014

Arc Resistance D495 seconds 240 142 (¼" Thick) (burns)

Dielectric Strength D149 volts/ Short Time .001" 0.005" film 2100 0.090" sheet 500 600

Loss Factor (0.040" sheet) D150 102 Hz 0.005 0.0122 103 Hz 0.005 0.0096 104 Hz 0.005 0.0106 106 Hz 0.024 0.0286

35

DELRIN® ACETAL HOMOPOLYMER

Delrin® acetal resins are ther­ moplastic polymers manufac­ tured by the polymerization of formaldehyde, which have gained widespread recogni­ tion for reliability of perform­ ance in many thousands of en­ gineering components all over the world. Since their commer­ cial introduction in 1960, they have been used in the automo­ tive, appliance, plumbing, con­ struction, hardware, electron­ ics and consumer goods indus­ tries among others. Parts made from Delrin® ace­ tal resins have a combination of physical properties not avail­ able with either metals or most other plastics due to the chem­ ical composition, regular struc­ ture and high degree of crystal­ linity of these resins. The out­ standing attributes of Delrin® are:

• High mechanical strength and rigidity • Fatigue endurance un­ matched by other plastics Delrin®acetal resins have good dimensional stabil­ • Excellent resistance to moisture, gasolines, sol- ity compared to other plastics over a wide range of vents and many other neutral chemicals. temperatures in atmospheres containing moisture, • Excellent dimensional stability lubricants and solvents. They find extensive use in • High resistance to repeated impacts industry for the fabrication of precision gears, bear­ • Good electrical insulating characteristics ings, housings and similar devices, because of their • Resiliency unique combination of dimensional stability with • Natural lubricity other properties, such as fatigue resistance and ten­ • Wide useful temperature range (in air:-50 to sile strength. However, as with all materials of con­ +90°C, -60 to +160° F, with intermittent use up to struction, there are factors affecting the dimen­ 160° C (320° F) sional stability of Delrin@which must be considered • FDA approval of certain Delrin compositions. when close tolerances are essential.

Effect of Moisture

DIMENSIONAL CHANGES OF "DELRIN" DIMENSIONAL CHANGES OF "DELRIN" WITH VARIATIONS OF TEMPERATURE WITH VARIATIONS OF TEMPERATURE AND MOISTURE CONTENT AND MOISTURE CONTENT

Erwlronmental Temperature °F Environmental Temperature °F

40 80 120 160 200 40 80 120 200 1.4 DELRIN 500 F, 900 F 1.2 Specimen Thickneu 3 mm (1/8")_.,,._"'+

.c 1.0 Q .c ...C i 0.8 t------!----+------,, ------,, ------< . 0.8

!l .5 .5 0.6 t ------1---. ,,. --+----- !. 0.6 . .".,_ ! .5 0.4 t-----1--,f'71''--t----:a---+ ---+ ------t 0.4 ..,_ 0.2

0

-0.2 '-----''------'-----+-----+--- -0.2 0 20 40 60 80 100 0 20 40 60 80 100 Environmental Temperature °C Environmental Temperature °C

36

CELCON® ACETAL COPOLYMER

Friction Dimensional Stability Friction generates heat which limits the useful life of a Many materials, including nylon, are affected by humid­ bearing. Also, friction causes wear, which increases the ity changes. Summer to winter humidity variation has cost of start-up and operation of machinery. Unlubricated caused press fit nylon bearings to fall out of housings due Celcon® has a low coefficient of friction which can help to shrinkage. Celcon®has excellent dimensional stability improve wear and reduce operating costs. in humid environments (See Figure 3). TABLE 5 - COEFFICIENT OF FRICTION AGAINST (Method ASTM D1894-61T): FIGURE 3 Steel 0.15 EFFECT OF MOISTURE ON NYLON 6/6 AND CELCON Brass 0.15 w 8.0 r---.-----.---,.---, ------0.04 Cl'.'. >­ :::, if) Aluminum 0.15 I- 7.0 0 (/) :a; CeIcon® 0.35 0 Nylon 0.17 ::;: 6. -r""'7---:/-----t--t-----+ ------0'.03 2 0 Note: The coefficient of friction of Celcon® acetal I- 5.0 :5 E w 0 ':'. copolymer against steel fs essentially constant over :::, 0 4.0 0.02 a temperature range of 70°F to 200°F (21°C to (/)w );! z 93°C). 3.0 w u, Cl'.'. u 2.0 ·-+-----+--+--+ ------j0.01 Friction is not a constant factor. It can vary with load, 0 sliding rate, finish of the materials, temperature and II- 1.0 if) S2 w humidity. In actual application conditions, Celcon® has w :a; 3: lower friction than most materials. Figures 1 and 2 show 2 3 4 5 6 0 the dynamic coefficient of friction of a Celcon®bearing as a IMMERSION TIME, WEEKS function of speed and load against a steel shaft. Unlike many materials, the friction of Celcon® is only slightly Fatigue Resistance affected by surface finish, temperature and humidity; in In reciprocating motion, or in cases where there is most cases these considerations can be neglected. much starting and stopping, fatigue resistance is impor­ Lubrication will reduce the coefficient of friction of Cel­ tant. Many materials, including , show con® to as low as 0.05. premature and unexpected failures due to fatigue.Celcon® has superior fatigue resistance and resilience, and is quite FIGURE 1 suitable for severe fatigue conditions (See Figures 4 and THE DYNAMIC COEFFICIENT OF FRICTION OF CELCON ASA FUNCTION OF THE s'LIDING RATE AT A CONSTANT BEARING LOAD (37.5 PSl/2.6 Kg/cm') AGAINST A 5). Celcon® has been used successfully in springs, self­ HARDENED AND POLISHED STEEL SHAFT returning switches and many other parts where fatigue could be a problem. 'it 0.400 ,----,----r--.----...-----, ------, i 6 In many cases intermittent operation actually increases e the usable bearing range of Celcon® acetal copolymer. LL Stop/Start operation does not build up heat as quickly as ::; 0.300 continuous operation, so higher loads can be used. Also, 1- wz Celcon®has similar static and dynamicfrictions(no slip or u stick), so cycf1c operation is satisfied. E 0.200 w 0 u u Corrosion and Chemical Resistance

:E 0.100 . .._ _ _, .. _ _,_ ...... 1 Corrosive conditions such as salt, hot water, chlori­ >- O 20 40 60 80 100 120 140 nated solvents, other solvents, and most chemicals do not o (6) (12) (18) (24) (30) (37) (43) attackCelcon® Celcon®iswidely used in marine applica­ BEARING SPEED FT.IMIN(M/MIN) tions where salt water severely limits the life of other FIGURE 2 materials. In solvent environments such as painting or dry THE DYNAMIC COEFFICIENT OF FRICTION OF CELCON ASA FUNCTION OF THE cleaning equipment, Celcon@remainsvirtually inert,allow­ MEAN SURFACE PRESSURE AT CONSTANT SLIDING SPEED (33 FPM/10MPM) ing quality operation and dependability. :§; AGAINST A HARDENED AND POLISHED STEEL SHAFT The chemical resistance of Celcon® acetal copolymer 0.400 r-----r---....----.---...----.---....--- 6 also means that process fluids or waste liquids from many systems can be recycled and used as lubrication. Celcon LeL Note: Lubrication will decrease friction to 0.05 can be used continuously in 180°F (82°C) water or in ::; 0.300 alkaline water. Soapy water has proven to be a very effec­ 1- wz tive lubricant in applications where oil or grease contami­ u: nation is not allowable. Innovative design could take LL 0.200 advantage of this in equipment for the food processing u industries. u Celcon® should not be used in strongly acidic environ­ 0.100 ...... _...... _..... , ments (pH 4.0) or in not oxidizing agents, such as hot 20% 0 0 50 100 150 200 250 300 350 hydrogen peroxide solution. Basic conditions, even (3.5) (7.0) (10.5) (14.1) 07.6) (211) (246) strongly basic systems like 60% sodium hydroxide, have BFARING PRESSURE PSI (Kg/cm2) little effect on Celcon®.

33

CELCON® ACETAL COPOLYMER

Table 1-1 - Typical Physical/Mechanical Properties

Nominal ASTM Test Specimen English M-Series GC25A Property Method Size (inches) Units Values Values Specific Gravity D792 1.41 1.59 Density lbs./ in. 3 0.0507 0.057 Specific Volume in.3 /lb. 19.7 17.54 Tensile Strength at Yield D638 Type I lbs./in. 2 Speed B 1/a -40°F 13,700 73°F 8,800 16,000 160°F 5,000 (at break) Elongation at Break D638 Type I % Speed B 1/a Thick -40°F M25/30 M90/20 M270/15 73°F M25/75 M90/60 M270/40 160°F 250 Tensile Modulus D638 Type I lbs./ in.2 410,000 1.2x106 1/a Thick Flexural Modulus D790 5x½x lbs./ in. 2 1/a Thick 73°F 375,000 1.05x106 6 160°F 180,000 0.7x10 220°F 100,000 0.5x106 Flexural Stress D790 5x½x lbs./ in. 2 13,000 at 5% Deformation 1/a Thick Compressive Stress at D695 1x½x½ 1% Deflection lbs./ in. 2 4,500 10% Deflection lbs./in.2 16,000 lzod Impact Strength D256 2½x½x¼ ft.Ib./ (Notched) machined in. notch notch -40°F M25/1.2

M90/1.0 M270/0.8 73°F M25/t.5 1.1 M90/1.3 M270/1.0 Tensile Impact Strength D1822 L-Specimen ft.lb ./ in.2 M25/90 1/a Thick M90/70 50

M270/60 Rockwell Hardness D785 2x¼ Disc M scale 80 Shear Strength D732 2x¼ Disc lbs./in. 2 73°F 7,700 13,000

120° F 6,700 160°F 5,700 Water Absorption D570 2x1/a Disc % 0.22 0.29 24-hr. Immersion

Equilibrium, 50% R.H. % 0.16 Equilibrium, Immersion 0.80 Taper Abrasion, 1000 g Load D1044 4x4 mg/1000 14 CS-17 Wheel cycles Coefficient of D1894 3x4 Dynamic Friction • against steel, brass, aluminum 0.15 • against Celcon 0.35

Many of the properties of thermoplastics are dependent upon processing conditions, and the test results presented are typical values only. These test results were obtained under standardized test conditions, and with the exception of specific gravity, should not be used as a basis for engineering design.

34

CELCON® ACETAL COPOLYMER

Celcon® acetal copolymer is an engineering thermoplastic SPECIFICATIONS which has a unique combination of properties. It offers a Thickness Tolerances balance of high tensile strength, shear strength, stiffness 1/8" to 1/4" thick ...... +.035" - .007" and toughness, and retains these properties over long 3/8" to 3/4" thick ...... +.050" - .008" periods of time in a wide variety of environments. These 1" to 1¼" thick ...... +.060" - .010" 1½" to 2" thick ...... +.187'' - .01O" properties, coupled with excellent fatigue endurance, 2½" to 4" thick ...... +.250" - .000" resilience, abrasion resistance and vibration resistance, light weight and a low coefficient of friction, make Celcon® Length and Width Tolerances 12"x48" ...... +1/8"-0" an ideal material for many gear applications. 24"x48", 48"x48"...... +1/4" - O" Like metals, Celcon® is justifiably classed among the 48"x96", 60"x120" ...... +1" - O" engineering materials, since its performance characteristics STANDARD COLOR: Natural. Black is available at a are of a high order, well-defined and predictable. In fact, premium. Celcon® is being used to replace metals not only because CELCON® 25% GLASS COUPLED ROD of cost, but also because of performance. Key functional Glass coupled Celcon® rod is an actual copolymer parts made from Celcon® (such as bearings, gears, cams, produced from Celanese GC25A resin. GC25A Celcon® etc.) are currently insuring the performance of products in offers improved dimensional stability, a greater load bearing capability, and maintains its high level of all areas of the marketplace. mechanical strength, stiffness and impact resistance through wide ranges of thermal and chemical environments. GC25A Celcon® is recommended for Properties of Celcon Acetal Copolymer industrial use ranging from gears and bearings to heavy The following section includes the mechanical, thermal duty conveyor links. Glass coupled Celcon® has wide application in the communications, appliance, automotive and electrical properties of Celcon® M90 (unfilled) and and plumbing industries. Celcon® GC25A as determined by standard tests (See GC25A rod meets Mil-P-46137 (MR), Type II, Grade A, Tables 1-1, 1-2 and 1-3). The values shown are typical 25 values that can be used to guide design work, but should class · AVAILABILITY not be used as specification minimums. Size Standard Lengths 1/2" through 2" diamater ...... 96" lengths One of the outstanding properties of Celcon® acetal 3" diameter and over ...... 48" lengths copolymer is chemical resistance. It is virtually inert to Non-standard diameters and lengths as available hydrocarbons and bases and is only affected by strong from stock acids (pH less than 4). In addition Celcon® may be used SPECIFICATIONS continuously in air at temperatures as high as 220'F (104'C) Size Tolerance and in water at temperatures up to 180'F (82'C).. 1/2" through 1" diameter ...... +.005" - .000" Intermittent use at higher temperatures can be tolerated in 1½" through 2" diameter ...... +.010" - .000" either environment. 3" diameter and over ...... +.125" - .000" STANDARD COLOR: Natural (off-white) CELCON® ROD CELCON® 25% GLASS COUPLED SLAB NATURAL CELCON IS FDA APPROVED Glass coupled Celcon® slab is an actual copolymer produced from Celanese GC25A resin. GC25A Celcon® AVAILABILITY offers improved dimensional stability, a greater load Size Standard Lengths bearing capability, and maintains its high level of 1/8" through 1" diameter ...... 96" to 120" mechanical strength, stiffness and impact resistance 1¼" through 2" diameter...... 96" through wide ranges of thermal and chemical 2¼" diameter and over ...... 48" environments. GC25A Celcon® is recommended for industrial use ranging from gears and bearings to heavy SPECIFICATIONS duty conveyor links. Glass coupled Celcon® has wide Size Tolerance application is the communications, appliance, automotive 1/8" through 1" diameter ...... +.002" - .000" and plumbing industries. 1¼" through 2" diameter ...... +.005" - .000" 2¼" through 3" diameter ...... +.030" - .000" GC25A slab meets Mil-P-46137 (MR), Type 11, Greade A, 3¼" diameter and over ...... +.125" - .000" class 25. AVAILABILITY STANDARD COLOR: Natural. Black Celcon rod is avail­ Standard Sheets able in diameters from 1/8" to 5" at a premium (standard sizes). 3/8" through 2" thick ...... 12"x48", 24"x48", 48"x96" 3" through 4" thick ...... 12"x48", 60"x120" Custom CELCON® SHEET AND SLAB SPECIFICATIONS AVAILABILITY Tolerances Standard Sheets...... 12"x48", 24x48", 48"x120", Length and Width ...... +.250" - .000" 60"x60", 48"x48", 48"x96", Thickness ...... ±10% 61"x121" - Untrimmed STANDARD COLOR: Natural (off-white\

31

CELCON® ACETAL COPOLYMER

Properties of Celcon® Bearings Celcon® offers a balance of structural and bearing copolymer with some degree of lubrication greatly properties that permits either innovation or direct improves performance. replacement. Also, because of its ease of molding and/or machining properties, it can be evaluated and Degrees of Lubrication produced inexpensively and quickly. A. Initial Lubrication A few drops of oil or a small amount of grease Advantages of Celcon® Bearings. should be applied before the bearing is in­ 1. Maintenance Free Operation stalled. Initial lubrication assists initial seating 2. Low Friction (Lubricated or Unlubricated) or wear-in of the bearing. This prevents abnor­ 3. Dimensional Stability during humidity changes mal heat build-up and allows a good wear re­ 4. Fatigue Resistance sistant bearing/shaft match to form. Initial lubri­ 5. Corrosion and Chemical Resistance cation will increase the life of a Ce/con® bearing 6. Creep Resistance up to ten times its unlubricated lifetime. 7. Noise Reduction Initial lubrication does not change the basic 8. Dielectric (Non-Conductive) in Electrical bearing characteristics of Celcon®; it simply im­ Applications proves break-in so that wear is reduced. 9. Compatibility with Common Shaft Materials B. Periodic Lubrication 10. Design Freedom Occasional oiling of the bearing is recom­ Although Celcon® offers many advantages, it does mended. Periodic lubrication increases both the have limitations. Plastics are thermal insulators and lifeof a Celcon®bearing and the usable range of have lower melting points than metals; Celcon® has a speed and load. Lubrication is constantly pres­ higher continuous use temperature limit (220°F [105° ent, so the bearing is separated from the shaft by C] in air) than most thermoplastics, but under an oil layer. Lubricated Ce/con® can be used in excessive loads or speeds, or with insufficient applications that are twice as severe as allow­ clearances, failure of a bearing will result due to heat able with unlubricated or initially lubricated build-up beyond the melting point of Ce/con®. Ce/con.® In general, Celcon® should not be used to replace C. Continuous Lubrication metal bearings when the load is above 1,000 psi (70 If there is a constant flow of lubricant through 2 Kg/ cm) , the speed is above 1,000 ft./min. (305 the Celcon® bearings, the ultimate in results is m/min), or the running temperature is above 220°F achieved. Continuous lubrication cools the bear­ (105°C). Prejudice against plastics can owhen an ing as well as separating the bearing and shaft. indiscriminate design is produced. Thus, plastics This type of system can satisfy high-speed should be used in specific bearing applications or in applications. controlled use general areas. The key requirement in selection of a lubricant is Where doubt may exist as to the technical aspects, that it not be acidic or decompose and yield acidic prototype testing should be used to develop the final products.since Celcon®is attacked and degraded by design of a Ce/con® bearing. strong acids. A partial list of suggested lubricants is Maintenance Free Operation given in Table 2. The lubrication need not always be Celcon® gives the engineer an alternate approach oil or grease; it could be soapy water, a process to bearing design. Celcon® has a low coefficient of fluid, or the product itself. friction against normal shaft materials; it is tough and fatigue resistant; it has good abrasion resistance; and Table 4 - Recommended Lubricants* it retains its properties over a wide temperature Uniflo Esso Division range. This combination allows it to be used Humble Oil and Refining Company unlubricated in many applications, including cameras Box 2180 Houston, Texas 7700 and projectors, sewing machines, toys, business machines, speedometers and hospital equipment. Lubriplate Fiske Brothers Refining Company 630-AA Lubriplate Division Unlubricated Celcon® bearings have developed an Newark, New Jersey 07105 excellent field use history. Silicone Oil Dow Corning Corporation If a higher level of performance or a longer life is #710 Midland, Michigan 48640 required, lubricated Celcon® should be used. The Refined Many Sources bearing/shaft contact in an unlubricated system can Mineral Oil be expected to give some wear. Combining the low 10W 30 Many Sources friction and abrasion resistance of Celcon® acetal Motor Oil *partial list

32

DELRIN® ACETAL HOMOPOLYMER

Physical Properties

ASTM DELRIN DELRIN ASTM DELRIN DELRIN PROPERTY No. Units DELRIN 500 CL AF PROPERTY No. Units DELRIN 500 CL AF Soecific Gravitv' D-792 - 1.42 1.42 1.54 Tensile Strength D-638 Mpsi

Rockwell Hardness D-785 - M94, M90, M78, (0.2 in./min) R120 R120 R118 -68'F 14.7 13.9 10.9 +73°F 10.0 9.5 7.6 Thermal Conductivity BTU in./ +158°F 6.9 6.6 5.3 hr. ft' 'F 2.6 - - +212'F 5.2 4.3 4.0 Coeff. of Linear D696 10-Sin./ +250'F 3.8 3.3 3.1

Thermal Expansion in. °F Modulus of D-638 Mpsi -40to +85'F 5.8 5.8 5.8 Elasticity +85 to +140°F 6.8 6.8 6.8 (0.2 in./min) +140 to +220°F 7.6 - - +73'F 450 450 420 +220 to +300° F 8.3 - -

Flexural Modulus D-790 Mpsi Specific Heat (0.05 in./min) Avg. over range 0 to +212'F - 0.35 0.35 - -68'F 530 550 520 +73°F 400 380 340 Water Absorption, +158°F 225 220 190 73'F D-570 % +212'F 130 130 110 24 hrs. immersion 0.25 0.27 0.20 +250'F 90 80 80 Equil., 50% R.H. 0.22 0.24 0.18 Flexural Yield D-790 Mpsi Eauil., immersion 0.90 1.00 0.72 Strength Coeff. of Friction Thrust (0.05in./min) (no lubricant) Washer +73°F 14.3 13.0 10.5 Static, +73' F Test2 - 0.20 0.10 - Dvnamic, +73'F - 0.35 0.20 0.14 Compressive D-695 Mpsi Stress Dielectric Constant D-150 (0.05 in./min) 50% R.H., 73° F, +73°F@ 1%Def. 5.2 4.5 4.5 2 6 10 - 10 Hz - 3.7 3.5 3.1 +73'F (iiJ 10% Def. 18.0 15.5 13.0

Dissipation Factor D-150 Shear Strength D-732 Mpsi 50% R.H.,+73° F, +73'F 9.5 9.5 8.0 10 6 Hz - 0.005 0.006 0.009 Deformation D-621 % Dielectric Strength D-149 V/mil 500 400 400 under Load Short Time 190 mils\ 1125 mils) (125 mils) 2,000 psi (ii) +122° F 0.5 0.7 0.6 Volume Resistivity D-257 Deflection D-648 'F 15 14 16 +73°F, 0.2%water ohm-cm 1 X 10 Sx 10 3x 10 Temperature Arc Resistance D-495 s 220 - 183 264psi 277 255 244 Flame extinguishes no no 66 Psi 342 338 334 self when arcing tracking tracking Flexural Fatigue D-671 Mpsi stoos 1120 mils\ Endurance Limit

Chemical Resistance Outstanding resistance to neutral chemicals including 50% R.H., +73° F, a wide variety of solvents4 10' Cvcles 4.7 4.0 3.6

Combustibilitv' UL-94 - 94HB 94HB 94HB Tensile-Impact D-1822 ft.lb.Jin'

Self lnnition Temp. ·o-i929 'F. 707 - - Resistance long +73°F 170 100 50 Flash lanition Temn. D-1929 'F 613 - - Unnotched lzod D-256 ft.i°b.lin. Tensile elongation D-638 % +73°F 100 at Break (no break) (0.2 in./min)

-68°F 38 13 15 Notched lzod D-256 ft.lb.fin. +73'F 75 40 22 -40'F 1.8 1.2 1.0 +73°F 2.3 1.4 1.2 +158'F 230 190 50 +212'F > 260 > 260 250 Melting Point D-2133 'F +250'F > 260 >260 > 260 (Fisher-Johns) 347 347 347

Availabilities Delrin (Rod) 1/8" to 6" dia. Nominal Lengths: Delrin®, Delrin AF®, Delrin 500 CL® 1/8" and 3/16" - 8 ft. 1/4" to 1" -10 ft. Delrin AF (Rod) 1/4" - 4" 1½" to 2" - 8 ft. Standard Sizes: 2¼" to 3" - 4 ft. 1/4" to 3" - 8 ft. 3¼" to 6" - 2 ft. 3½" and over - 3 ft. (Slab) 1/16" - 4" (Plate) 1/4" to 2" Slab Sizes: Standard Size: 1/16" to 4" - 12" X 48" 24" X 48" 1/8" to 2" 24" X 48" Delrin 500 CL Custom ordered, in rod only.

37

DELRIN® AF AND DELRIN® CL

Delrin® AF is a unique thermoplastic Features User Benefits consisting of oriented TFE fibers uniformly dispersed in acetal resin. This combination Mechanical and Electrical produces a material with higher surface • Strong, stiff, and tough • Structural design lubricity than unmodified acetal, while re­ • Fatigue resistance • Low cost, integral taining acetal's strength, dimensional sta­ springs • Non-conductor • Electrical and thermal bility, and toughness. insulation The outstanding properties of Delrin® AF Wear and Friction are those associated with sliding friction. • Low wear and friction • Improved performance Bearings made from it will sustain high and reliability loads when operating at fast speeds and • Low stick slip • Smooth operation and will show little wear. In addition, bearings less starting torque will be essentially free of slip-stick behavior • No lubrication required • Reduce maintenance and product because the static and dynamic coeffi­ contamination cients of friction are almost equal. Delrin® Aesthetics AF is being used for bearings df several • Smooth surfaces • Eliminate painting basic designs, in a variety of applications. • Attractive surface Its high performance as an unlubricated Low Production Costs bearing surface has been the driving force • Easy fill and mold • High productivity at for its acceptance. Additional areas of use release low costs are gears, cams, and other moving parts • Assembly by snap fits • Easy to mold complex or welding parts which need excellent frictional properties, • Multifunctional design • Lower assembly costs resistance to wear, and ease of fabrication. (i.e., one part per­ • Lower manufacturing In addition to lower friction, bearings and forms function of four) costs moving parts made from Delrin®AF show • High productivity at • Less inventory and low costs assembly one of the highest degrees of wear resist­ ance obtainable in a thermoplastic bearing material.

Delrin® 500 CL Typical Applications

Delrin® 500 CL acetal resin is a new • Counter Assemblies • Switch Mechanisms thermoplastic resin which combines low • Conveyor Parts • Business Machines wear and frictional properties with strength, • Clocks and Watches • Calculators impact resistance, good processability and • Record Changers • Lock Assemblies colorability. It consists of a uniformly dis­ • Meters • Gears, Bearings and persed chemical lubricant additive in Del­ Springs rin® 500. Delrin® 500 CL is easily machined and equal to or better than soft brass. It can be sawed, drilled, turned, milled, shaped, reamed, threaded and tapped, blanked and punched, filed, sanded and polished.

38

ERTALON® LFX

ERTALON® LFX is an internally lubricated cast nylon, Key Benefits Availabilities specifically developed for unlubricated moving-parts applications. The evenly dispersed non-toxic and "free" • Lower and constant Rod lubricant, built-in during the casting process, remains an coefficiency of friction Diameter: 2" to 8" integral part of the material and gives an enduring and • Lower heat build-up, considerable improvement in the sliding properties. hence higher load­ Plate carrying capacity (can Thickness:¼" to 4" Outlasts Conventional Cast Nylon double the PV-limit) Size: 48" x 48" Comparative bearing tests on steel mating surfaces have • Longer life Also available shown that ERTALON® LFX outlasts conventional cast nylon • Less stick-slip 1" to 1 ¾", 24" X 24" on wear resistance by a factor which can be as high as 10, • Better machinability 2" and over, 12" x 12", and perhaps even more important, the coefficient of friction 12" x 24" and 24" x 24" is reduced by 50% or more.

ERTALON®

Properties Method Units LFX Specific gravity D792 1.13 Water absorption D570 Immersed, 73°F, 24 hrs. % 0.55 Saturated, 73°F, 50% RH % 1.80 Saturated in water, 73°F % 6.50

Mechanical properties (1) Tensile strength at yield (2) D638 psi 10,200 Elongation at yield (2) D638 % 5 Tensile strength (2) D638 psi 10,000 Elongation at break (2) D638 % >10 5 Tensile modulus (3) D638 psi 4.1 X 10 Impact strength, notched (Charpy) D256 ft-lb/in 0.50 Rockwell hardness D785 M scale 80 Thermal properties OF Melting point 430 Coefficient of linear thermal expansion

6 Average between 70° and 140°F in/in/°F 44 X 10· 6 Average between 70° and 210°F in/in/°F 50 X 20· Thermal conductivity C177 BTU-in/hr-ft2-°F 2.0 Maximum seNice temperature in air (RH<80%) OF Short term (4) 320 OF Continuous (5) 210

Deflection temperature under flexural load D648 at 264 psi °F 165 OF at 66 psi 340

(1) The figures given for the mechanical properties of ERTALON 6, 66 and LFX are average values of tests run on specimen machined out of rod 2 in. (2) Test speed 0.2 ipm (3) Test speed 0.04 ipm (4) Only for short time (a few hours) exposure in lightly loaded applications. (5) Temperature resistance over a period of several months to several years. During that time, changes in physical properties occur due to thermal degradation (heat aging). Practice has shown that these changes are still acceptable as to the performance of technical parts. Important: the max. temperature of use also depends very much on the load level. (6) Measured on a 5/64" thick sheet.

39

FLUOROCARBONS

There are several basic members of the fluorocarbon Electrical - Low power factor, low dielectric constant, non­ (or fluoroplastics, as they are sometimes called) family. variant over an extremely wide range of frequencies. Most widely known are the two described Dielectric strength of thin sheeting will run 1000 to 2000 below: polytetrafluoroethylene {TFE) and polytrifluoro­ volts per mil in short time tests, but material will fail at lower chloroethylene (CTFE). voltages under prolonged electrical stress. Volume and surface resistivity are high, and little affted by moisture. A newer variation is fluorinated ethylene propylene (FEP) Resistance to arc over is excellent, and on failing, material which exhibits many of the same properties as TFE, but has melts and vaporizes, rather than carbonizing and leaving a the added advantage that it can be processed in conducting path. conventional thermoplastics equipment. Newer still is vinylidene fluoride, a flurocarbon that offers excellent Molding "Teflon" is not adapted to being molded by the chemical resistance, inertness to moisture, weathering, and conventional techniques used with other plastics, because oxidation, and retention of physical properties within a the polymer does not melt and flow. It is, rather molded by temperature range of -80 to 300° F. a process roughly comparable to that used in powder metallurgy, which depends on the fusion of solid particles Polytetrafluoroethylene (TFE) that have been compressed into a mass of the desired Characteristics - Thermoplastic, opaque, relatively soft shape. The polymer does not reach a fluid condition under and flexible. Tends to cold flow under pressure, slippery to high temperature, but at 620°F. it undergoes a transition touch, low surface friction. Does not have the wear from the normal crystalline state to an amorphous gel, and resistance of Nylon. Recommended that service this is the factor upon which the molding process depends. temperatures be kept below 480°F. Surface is easily dented Finished articles can be molded directly from "Teflon" and scrated. Surface tends to be self lubricating. powder provided the design is relatively simple and free Applications - Spaces for coaxial cables, inserts for from offsets. Rather obvious limitations on shape are coaxial connectors, antenna insulators, coil and condenser imposed by the lack of flow during molding and the insulation, high temperature insulation for motor leads, tendency, when flow is forced by excessive pressures, to thermocouples, industrial heating wire, motor housings, develop fractures that will not reweld. commutator segments, resistors, gaskets, pump In specifying dimensions for any article that is to be packagings. molded from "Teflon" it is well to remember that it is a Advantages - Extreme chemical inertness, high heat relatively flexible material, as compared to most plastics. resistance, non-adhesiveness, toughness, low dielectric Hence its ability to conform is exceptional and this makes loss over a wide temperature range, low water absorption. close clearances and tolerances unnecessary. Stability at high temperatures is outstanding. No So far no usable cements have been found. appreciably lower tensile strength at 522°F. than at room temperature. Can be held for long times at high "Teflon" meets the classical definition of an organic temperature. Can be held for long times at high temperature compound as a compound or carbon, for it is a polymer of with but slight change. Does not have a melting point in the tetrafluoroethylene (C2F4). It has a carbon-to-carbon chain, normal sense, but undergoes a solid phase transition with two atoms of fluorine attached to each carbon: around 620°F. with sharp drop in strength. Not embrittled at FFFFFF low temperatures. Films can be flexed without breaking -C -C -C -C -C-C­ below minus 100°F. F FF FF F Disadvantages - Not easily cemented, cannot be molded It is the hydrogen in ethylene {C2H ) which has been by conventional techniques, cannot be plasticized, 4 generates toxic fumes at high temperatures, high cost of replaced by fluorine. The carbon is still there, holding things together. material. Chemical - Chemical resistance is phenomenal. Light and TRADE NAME-TEFLON, HALON age have no detectable effects, water absorption is zero. Withstands attack by practically all chemicals except molten alkali metals. Fluorine gas at 300°F. has a slight effect on moldings Chlorine trifluoride attacks at elevated temperatures. Acids, alkalies, oxidizing agents and most solvents have no effect on these plastics. Forms - Molding powder, sheets, rods, tubes, film tape, molded shapes, machined parts, fabric coatings, metal finished, wire enamels, liquid dispersion, does not melt or flow, simple shapes can be compression molded, sintered and machined. Can be extruded by special methods. Coating and impregnation can be accomplished through the use of suspensoids. Formulations have been developed which display excellent adhesion to metal and provide protection from corrosion. Among the polymeric materials on the market, polytetrafluorethylene is the outstanding one in three major properties - heat resistance, chemical resistance and low electrical losses.

40

FLUOROCARBONS

Teflon® (polytetrafluoroethylene) is among Typical Uses for Teflon® the more expensive fluorocarbons. Design VALVE COMPONENTS engineers havefound Teflon®to be adapta­ v-rings cup-and-cone packings ble to a variety of requirements because it solid ring packings a-rings offers a unique combination of heat resis­ seals plugs tance, low friction, and good chemical and sleeves inserts electrical properties. Fluorocarbons can be swivels seals used over a wide temperature range, from GASKETS solid gaskets as low as -0° F to as high as 500°F. gaskets bonnet gaskets PUMP COMPONENTS Parts fabricated with TFE resins exhibit bearings thrust washers high strength, toughness, and self-lubrica­ shaft packing seals tion at low temperatures. These fluorocar­ seal faces seal rings bon resins are virtually unaffected by most cup seals pistons chemicals. Teflon® also exhibits the lowest piston rings piston packing dielectric constants and lowest dissipation OTHER CHEMICAL EQUIPMENT dip tubes factors of all solid materials. backup rings seal rings for pipe flanges seal rings for plastic pipes Properties Relatively Independent seal rings for threaded fittings solid pipe tees of Fabrication Conditions elbows adapters Chemical Properties cups containers Resistance to corrosive reagents antistick linings stirring rods (laboratory) Nonsolubility baffles Long-term weatherability rotameter components separators Nonadhesiveness stopcocks distillation tower packing Nonflammability MECHANICAL COMPONENTS bearings seals Electrical Properties rings conveying rollers Low dielectric constant door slides skids Low dissipation factor washers High arc resistance ANTISTICK USES bread-sheeting rolls High surface resistivity heat-sealer plates guides, hoppers, and dead plates in High volume resistivity snow-plow blades dirt-plow blades TAPE-WRAPPED WIRE Mechanical p·roperties hook-up distribution and power transformers Flexibility at low temperatures aircraft, integral and fractional motors coaxial cable for radar and television Low coefficient of friction high-voltage wiring Stability at high temperatures high-temperature wiring spacers for coaxial cable MOTORS AND GENERATORS coil wrappers slot liners coils (taping) coil separators conductor insulation for armature or field TRANSFORMERS AND COILS conductor, layer, and ground insulation coil separators ELECTRONICS EQUIPMENT inserts for coaxial connectors coaxial spacers bases for subassemblies terminals standoff and feedthrough insulators layer insulation coil separators

41

FLUOROCARBONS

Recommended Tolerances for Machined Parts of TFE-Fluorocarbon Resins Machining Operation Tolerance* Turning/boring: All dimensions (OD, ID, and lengths) up to 1 in ...... ±0.0015 in. For each additional inch of dimension (OD, ID and length) add a further tolerance of ...... ±0.001 in. ID tolerance based on a length to diameter ratio no greater than ...... 1.5 to 1.0 Concentricity-Total indicator reading (TIR) for relation. of OD to ID ...... 0.006 in. Angles ...... ,...... ±1/2 degr. Drilling/reaming: Reaming of TFE parts is not generally recommended due to build-up of frictional heat in tool Diameter of drilled hole tolerance based on a length to a diameter ratio not to exceed 5.0 to 1.0 Location and depth of drilled hole ...... ±0.015 in. Milling: All dimensions ...... ±0.005 in.fin. Angles ...... ±1/2 deg. Sawing: +0.060 in. All dimensions ...... 0.000 in. Grinding: Face or flat grinding is usually not performed on TFE parts, but where this process is required tolerances are to be agreed upon between the purchaser and the seller Centerless grinding: Dimensions up to 1/4 in...... ±0.0005 in. Dimensions from 1/2 in. to 1 in ...... ±0.001 in. For each additional inch or part of inch add a further tolerance of ...... ±0.0005 in. Soak time: All dimensions to be measured after soak at mean established inspection temperature not less than ...... 24 h Finish: When specifying surface finish on machined TFE parts, the method of measurement must also be specified. Even when surface measurement instruments are properly used, rms, surface finish reading will range ±50% and tolerances should be specified. When performance is a function of finish, inspection techniques should be agreed upon between the purchaser and the seller. It should be pointed out that, since one is considering a material that under­ goes plastic flow and material transfer, the surface finish (per se) is not as critical as it is for metals.

Availability Teflon - Availabilities Sheet-1/16" to 2" thickness Thickness Tolerances 1/16" thru 1/8" - ±.010" 3/16" and over - ±8% Standard Sizes 1/16" to 1" - 24"x24", 36"x36", 48"x48" over 1" -12"x12", 24"x24" Rod-1/8" to 6" dia. (extruded) Tolerances Up to 1" - +.002" - .000" 1" to 4" - +.020" - .000" 4¼" to 6" - +.125" - .000" Standard Length - 6 ft. 4¾" to 11" dia. (molded) Tubing-1/16" to 2" (flexible) 1/16" to 2" (extruded) Random Lengths - 2-6 ft. std.

42

FLUOROCARBONS

Properties

Test

Method TFE .0003 Property Units ASTM Fluorocarbon Specific Gravity 0-792 2.1-2.3

Tensile Strength psi 0-638 1,500-5,0001

Elongation % 0-638 75-350

Tensile Modulus of Elasticity psi 0-638 50,00-90,000

Flexural Strength psi D-790 No Break

Flexural Modulus of Elasticity psi 0-790 90,000-110,000 .0002 Compressive Strength @ Yield psi 0-695 No Yield Point u:- Coefficient of Compressive Modulus of 0 Elasticity psi 0-695 95,000-115,000 ...., Expansion ---+ C Coefficient of Friction :.::; (Dry vs. Steel) Dynamic .04-.10 C Hardness ·0en Rockwell "R" 0-785 10-20 C .0001 Durometer "D" 0-676 55-70 X OF UJ Heat Deflection (264 psi) 0-648 100-140 0 Deformation Under Load C: Q) 122°F., 2,000 psi % 0-621 9-11 i Coefficient of Linear Thermal ai 0 Expansion in./in./°F 0-696 () in./in./°F x 10-s

- 86°F to 86°F 5.5- 7.5 -100°F to -150°F

Melting Point OF 0-789 621± 9°F

Dielectric Strength volts/mil 0-149 500-650

Volume Resistivity OHM-CM 0-257 15 10 Dielectric Constant 0-150 2.0-2.1

Dissipation Factor (lmhz) 0-150 < .0005

Water Absorption-24 hours % 0-570 .00-.05 "I' ----,.-----,-----,.-----, ------, -100 0 200 400 600 Unusual Chemical Resistance ... inert to practically all chemicals and °C-200 -100 32 100 200 300 solvents. The only commercial chemicals and solvents that affect TFE are Thermal Expansion of TFE-Fluorocarbon Resin molten alkali metals, and certain halogenated chemicals at high tempera­ tures and pressures.

Weather Resistance. . . virtually unaffected by outdoor weathering. Sam­ ples exposed for over twelve years show no change in properties.

1 ASTM 0-1457 used for thin specimens. Property data shown are typical average values and will vary on specific production lots. They, therefore, should be used only as a guide to primary selection for application of a given material and never for purchase specifi­ cations. Further technical information is available for specific application requirements. Linear Thermal Expansion vs. Temperature 5 I 4 J

Linear Coefficients of Expansion a'< 3 / c Temperature Linear Coefficient of Expansion 0 Range,°F ·en (10-Sin./in./° F.) C 77 to -310° 4.77 CL / 2 "X 77 to -238° 5.33 UJ 77 to -148° 6.21

43

FLUOROSINr500 & 207

Fluorosint® 500 Availabilities Fluorosint® 500 is a synthetic mica filled TFE fluorocarbon developed to SHEET improve the mechanical and thermal properties of unmodified TFE without Thickness: 1/4" to 3" affecting its unique electrical and chemical properties. Sheet Sizes Available: 12" x 12" in all ticknesses Because of this mica additive, Fluorosint® 500exhibits a variety of improved Tolerances: performance characteristics over pure TFE. With its low coefficient of thermal Thickness ±15% Width and Length +1/4" - .000" expansion, Fluorosint® 500 hasawide continuous service temperature range and

has the added advantage of operating at substantially higher temperatures for limited periods. This low coefficient of thermal expansion, approximately one­ half that of TFE, virtually eliminates fit and clearance problems in parts made ROD from Fluorosint® 500. Diameters: 1/2" to 8¾" Lengths: Fluorosint®500 features excellent electrical properties. Its low dissipation rate 1/2" to 1¼" dia. 4' nominal over a full range of use temperatures leaves it virtually unaffected by frequency 1½" to 4" dia. 12" nominal changes. Similar to TFE in dielectric strength, combined with its heat resistance, Over 4" dia. 6" nominal and surface and volume resistivity, Fluorosint® 500 is an ideal material for coil Tolerances: 1/2" to 3/4" dia.: ±.001" forms, stand-off insulators and electrical insulating wear parts. 1" to 1½" dia.: +.010" - .000" 1¾" to 4¾" dia.: +.125" - .000" 5" to 8¾" dia.: +.250" - .000" Fluorosint® 207 Fluorosint® 207 is a mica filled TFE; filled at approximately half the level of Fluorosint 500. The lower level of mica content results in a more ductile MOLDED TUBING materials that exhibits a higher coefficient of thermal expansion. Fluorosint Available in 1½" to 12" O.D. with 207 is superior to glass-filled TFE in certain mechanical properties. Tests and wall thickness of 1/2" to 3" in field experience indicate that Fluorosint 207 is also less abrasive on mating lengths of 6" and 12" metal parts than similar glass-filled TFE.

The optimum blend of synthetic mica and TFE which comprises Fluorosint 207 makes it an outstanding material for use in steam service and hot air TYPICAL APPLICATIONS applications. It retains its form stability to approximately 550°F, and is used Valve Seats Stand-off insulation typically in ball valve seats, butterfly valve seats, seal rings and gaskets that Insulator wear parts require the particular advantages of this material. Bearings Bushings Slides Seal rings Gaskets Washers

Compare Fluorosint Performance

44

PROPERTIES OF FLUOROSINT®

Test Method Fluorosint Fluorosint Property Units ASTM 500 207 Specific Gravity D-792 2.25-2.35 2.25-2.35 Tensile Strength psi D-638 750-1,200 1,000-1,500 Elongation % D-638 1-10 3-25 Tensile Modulus of Elasticity psi D-638 375,000-600,000 300,000-450,000 Flexural Strength psi D-790 1,500-2,500 2,000-3,000 Flexural Modulus of Elasticity psi D-790 525,000-630,000 350,000-450,000 Compressive Strength No Yield @Yield psi D-695 4,500-5,200 Point Compressive Modulus of Elasticity psi D-695 275,000-325,000 225,000-275,000 Coefficient of Friction (Dry vs. Steel) Dynamic .1-.2 .04-.2 Hardness Rockwell "A" D-785 45-65 40-60 Durometer "D" D-676 64-74 64-74 Heat Deflection (264 psi) OF. D-648 240-300 200-220 Deformation Under Load (122°F., 2000 psi) % D-621 0.80-1.10 2.25-2.85 Coefficient of Linear Thermal Expansion in.fin.IF D-696 in.fin.IF. x 1o-s - 86°F. to 86°F. 1.25-1.50 3.25-4.50 - 100°F. to - 1 50°F. 1.25-1.50 2.50-3.00 Melting Point OF. D-1457 621 ± 9°F. 621 ± 9°F. Dielectric Strength volts/mil D-149 275-300 200-250 Volume Resistivity OHM-CM D-257 >1013 >1012 Dielectric Constant D-150 2.85-3.65 2.65-2.85 Dissipation Factor (lmhz) D-150 .005-.010 .005-.010 Water Absorption 24 hours % D-570 <1.0 <.35

Unusual Chemical Resistance... inert to practically all chemicals and solvents.

Weather Resistance ... virtually unaffected by outdoor weathering.

Property data shown are typical average values and will vary on specific production lots. They, therefore, should be used only as a guide to primary selection for application of a given material and never for purchase specifications. Further technical information is available for specific application requirements.

45

HALAR®- ECTFE

Properties Chart

Property Test Method Values & Units HALAR® ECTFE Fluoropolymer is the new standard for protection against GENERAL corrosion and maintains purity in the Specific gravity D792 1.68 g/ml chemical processing, semiconductor and Water absorption D570 <.1% Oxygen index D863 60% related industries. HALAR's® exceptional Flammability UL-94 V-O chemical resistance, temperature performance to 300°F, mechanical MECHANICAL properties and ultra purity make it the Tensile strength@ yield D638 4500 psi perfect choice for valves, pumps, tanks or Tensile strength@ break D368 7000 psi any application requiring exceptional Elongation @ break D638 200% performance in fluid handling. Tensile modulus D790 240,000 psi Flexural modulus D790 240,000 psi Notched lzod impact D256 no break @ 73°F Markets Hardness Rockwell D785 R93 Taber abrasion D1044 5mg/1000 cycles • Chemical Processing Rad resistance 200 M Rad • Petrochemical • Pulp and Paper THERMAL • Pharmaceuticals Melt point D3418 437°F • Semiconductor Processing Heat distortion temp D648 240°F @ 66 psi (D.I. Water System) Thermal conductivity C117 1.09 BTU in/hr/ft/°F Coefficient of expansion D696 10x1Q·5 in/in @ 122-185°F Applications Maximum service temp 356°F Continuous service temp 300°F • Solid and lined pipe • Fittings ELECTRICAL • Pumps Dielectric constant D150 2.5 • Filter housings Dielectric strength D149 500 v/mil (80Kv/mm) • Tanks and tank linings Dissipation factor 10 Hz D150 .009 • Valves 15 Volume resistivity D257 10 ohm/cm Stock Shapes

ROD Material Characteristics Diameter: 1/2·, 1 ", 1½", 2 11 , 3 11 , 4 11

Purity Excellent: contains no fillers, lubricants or Standard Lengths: ½" to 2"-96" plasticizers to leach into and contaminate contents. 3" to 4"-48"

Chemical Excellent: virtually unaffected by most common SHEET Resistance corrosive chemicals including strong mineral and Thickness: .060"-.090" oxidizing acids, alkalies, metal etchants, liquid .125"-.250" oxygen and essentially all organic solvents except hot amines and ketones. Standard Sizes: 24" x 48" 48" X 96" Permeation Excellent: extremely low permeability to liquids, Resistance gases and vapors; 10 to 100 times better than PTFE Standard Color: Natural Off-White Other standard Halar shapes are available. Special sizes in rod, or PFA to oxygen, carbon dioxide, chlorine gas and sheet and tube are available on custom quotation. hydrochloric acid even at elevated temperatures.

Abrasion Excellent: the toughest of all fluoropolymers, nylon­ Resistance like in durability with excellent mechanical properties and impact strength.

Temperature Excellent: performs reliably under continuous use Performance from -105°F to 300°F.

46

HYDLAR®-ECTFE HYDLAR® is a unique engineering thermoplastic that is both long-wearing and affordable. Reinforced with the lightweight strength of KEVLAR® aramid fiber, HYDLAR® is able to meet the high performance standards required of aerospace, automotive and industrial applications. BENEFITS OF HYDLAR® • In instances where reinforced nylon and other thermoplastics normally wear out, the slippery, long-lasting properties of HYDLAR® offer superior wear resistance and high impact strength. • Metals require lubrication. High-temperature resistant plastics are hard to get. Both are expensive. • Only HYDLAR® offers higher heat deflection in both intermittent and constant temperature ranges at a moderate price. • HYDLAR® offers excellent stiffness, proving higher in tensile strength and flexural modulus than other thermoplastics. WEAR HEAT RESISTANCE PRICE Vespel® Excellent Excellent $(87x) Torlon® Good Very Good $(21x) Bearing Bronzes Good Very Good $(6x) HYDLAR® Excellent Good $(4x) Common Engineering Plastics Average Average Base Price

HYDLAR®Z A blend of Du Pont ZYTEL® nylon filled with Du Pont KEVLAR® arimid fibers. The KEVLAR® filler enhances the physical properties but is not abrasive like glass fillers. KEVLAR® increases the tensile and flexural strength and also increases the impact and heat properties. COMPARATIVE MECHANICAL PROPERTIES PRIMARY APPLICATIONS: MOLDED EXTRUD ED • Pulleys Test MOLDED AND EXTRUDED ONLY MOLDED Units Nylon* Nylon** Nylon* Nylon* Hydlar z· • Bearings (Heavy load) 6/6 6 6/6 6/6 6/6 • mandrels Fiber - None Glass Glass Glass Nylon/Kevlar • Casters Content % -0- 10% 13% 33% N/A • High strength wheels Tensile Strength PSI x 103 12.0 14.0 15.0 27.0 20.0 Tensile Modulus PSI x 10' - .9 - - 1.3 • Rollers Elongation % 60.0 3.2 2.0 3.0 4.0 • Wear plates Flexural Strength PSI x 10' - 18.0 - - 23.0 Flexural Modulus PSI x 10' .41 .6 .7 1.3 .9 Chemical Resistance: Notched lzod Impact Ft-lb.fin. 1.0 1.1 .9 2.0 2.7 • Same as ZYTEL® Compressive Strength PSI x 103 13.0 14.5 - 24.0 19.3 Test Distortion Temp Physical Properties: @264 PSI Of 194 370 470 480 470 Service Temperatures 275° F Coefficient of Linear Thermal Expansion in/inl°F 4.0x105· - 1.5x10·' 1.3x10·' 1.6x10·' Tensile Properties: Specific Gravity gr/cm' 1.14 1.21 1.22 1.38 1.16 • Modulus - 1.3 million psi Water Absorption 24 hrs. Immersion, 73°F % 1.2 - - .7 .8 • Flexural strength -23,000 Saturation, 73°F % 8.5 - 7.1 5.4 6.3 • Compressive strength - 19,300 Wear Factor••• - 867 to 149-Melting N/A 424 128 to 79 1105 of nylon 6 (Hydlar* ZM) Other Physical Properties: Galling of Mating • Wear Factor - 128 to 79 Test Surface - Minor Heavy - Severe None • Galling of mating surfaces - none •DuPont Zytel Property Charts except wear ..,ATP Test Data except wea r**"ASTM Thrust Washer Test: PV=2,500 P=250 PSI, V=10 f.p.m.

HYDLAR®G A blend of PPS (polyphenylene sulfide) and KEVLAR® arimid fibers. The PPS imparts excellent chemical resistance and dimensional stability. It is an excellent material for harsh chemical environments where high strength is needed. PRIMARY APPLICATIONS: • Bushings (In water) • Compressor vanes HYDLAR • High temperature applications - Bushings Prooerties ASTM Units Values Chemical Resistance: Tensile Strength D638 psi 12.0x10' • Solvents - excellent Tensile Modulus D638 psi 1.4 x 105 • Acids and caustic solvents - fair Flexural Strength D790 psi 18.0 X 103 6 • Oxidizing acids - poor Flexural Modulus D790 pis 1.1 X 10 IZOD impact, Notched D256 ft-lb/in. 2.6 Physical Properties: Heat Distortion at 264 psi D648 OF 485 Service Temperature 485°F Specific Gravity D792 g/cm 3 1.25 Coefficient of Linear Tensile Properties: 3 • Modulus - 1.4 million psi Thermal Expansion D696 in.fin. °F 1.5 X 10· • Flexural strength - 18,000 Water Absorption D570 % <<.08 • Tensile strength - 12,000 Wear Factor Thrust washer - 210 Coefficient of Friction Thrust washer - .35 Other Physical Properties: ® Hydlar is a registered trademark of A.L. Hyde

47

HYDEX®101,202,301,302 HYDEX 101, 202, 301 and 302 Rod and Slab stock are a PHYSICAL PROPERTIES family of rigid thermoplastic polyurethane products. HYDEX • Clarity • Toughness products are produced from lsoplast* engineering thermoplastic resins. lsoplast resins (HYDEX) are unique in • Chemical Resistance • Wear Resistance the fact that they are amorphous which will yield properties • Dimensional Stability • Low Moisture such as good impact resistance, good dimensional stability • Impact Resistance Absorption and clarity approaching that of polycarbonate, but they also exhibit properties of crystalline polymers by having excellent TYPICAL APPLICATIONS chemical resistance and low moisture absorption. • Small Engine • Gears Components • Bearings Four grades of this resin are available: HYDEX 301 and 302 are transparent grades, HYDEX 101 • 011 And Gas Field • Industrial Processing and 202 are opaque but have higher impact properties than Equipment Equipment that of the other two grades. • Industrial Hardware • Level Gauges A wide variety of rod and slab sizes are available. - Nuts • Filter Housings Bolts Although HYDEX 101, 202, 301 and 302 have unique properties which make it a good candidate for metal, glass or ceramic replacement, it can also be used for replacing or in similar applications where polycarbonate, nylon or acetal are currently used.

PHYSICAL HYDEX HYDEX HYDEX HYDEX PROPERTIES ASTM UNITS 101 202 301 302 • Tensile Strength, Yield D638 psi 7,000 9,000 10,000 12,000 • Tensile Strength, Ultimate D638 psi 7,000 9,000 9,000 10,000 • Tensile Elongation, Yield D638 % 8 9 7 9 • Tensile Elongation, Rupture D638 % 180 90 140 90 • Tensile Modulus D638 psi 220,000 260,000 310,000 340,000 • Flexural Strength D790 psi 10,000 12,000 14,000 16,000 • Flexural Modulus D790 psi 260,000 280,000 340,000 360,000 • lzod Impact (Notched) D256 ft•lb/in 22 10 2 2 • Hardness, Rockwell D785 R 116 123 M 48 74 L 80 109 • Heat Deflection Temperature D648 OF

Uannealed, 66 psi 160 265 190 270 Uannealed, 264 psi 140 240 170 240 • Heat Deflection Temperature D648 OF

Annealed, 66 psi 180 290 220 280 Annealed, 264 psi 170 280 210 290 • Water Absorption D570 % .17 .15 .19 .14 (24-hours) • Transmittance D1003 % opaque opaque 88 88

48

HYO EX® - PHYSICAL PROPERTIES COMPARISONS HYDEX 101, 202 and 302 made from lsoplast~ resin is a rigid thermoplastic polyurethane with properties that make it an excellent choice for many industrial applications. It is used as a replacement for metals in many applications. In industrial equipment, it is used in many harsh chemical environments for gears, bushings, valves for fluid handling, and many other uses.

Being a relatively new resin, it has found success in replacing many commonly used plastics. This data sheet will compare HYDEX 101 and 202 to Nylon's, and HYDEX 302 to polycarbonate.

PHYSICAL HYDEX HYDEX ST810 ZYTEL PROPERTIES ASTM UNITS 101 202 NYLON 42 • Tensile Strength, 73°F D638 psi 7,000 9,000 7,500 12,400 • Tensile Elongation, Break D638 % 180 90 60 90 • Flexural Modulus D790 Kpsi 220 260 245 410 • Impact Strength D256 ft-lb/in 22 10 17 1.2 • Water Absorption D570 % .17 .15 1.2 1.2 • Heat Deflection Temperature D648 OF 264 psi 170 280 160 194

PHYSICAL HYDEX PROPERTIES ASTM UNITS 302 POLYCARBONATE • Tensile Strength D638 psi 10,000 9,500 • Tensile Elongation D638 % 90 110 • Tensile Modulus D638 Kpsi 340 345 • Flexural Strength D790 psi 16,000 13,500 • Flexural Modulus D790 Kpsi 360 340 • lzod Impact (Notched) D256 ft-lb/in 2 14 • Heat Deflection D648 OF 270 280 • Hardness, Rockwell D785 74 70 • Chemical Piesistance EXCELLENT POOR

In addition, machine grade polycarbonate is not optically clear and is difficult to polish to achieve clarity. HYDEX 302 can be successfully polished to achieve excellent clarity and light transmission.

CHEMICAL RESISTANCE DATA Rating Method

E - Excellent, the material appeared to be unaffected by the chemical during the test. G - Good, the material seemed to be only slightly affected by the chemical during the test. F - Fair, the material was substantially affected by the chemical during the test. P - Poor, the material was severely attacked by the chemical during the test.

Material Length of Grade Chemcial Rating Exposure (days) Temp. • 101 Acetic Acid 5% E 28 73 F • 301 AceticAcid 5% E 28 73°F • 101 Acetone p 28 73F • 301 Acetone p 28 73°F • 101 ASTM Fuel A E 28 73 F • 101 ASTM #1 Oil E 28 73°F • 101 Clorox Bleach E 28 73°F • 301 Clorox Bleach E 28 73°F • 101 HydrochloricAcid, F 28 73°F Concentrated • 301 HydrochloricAcid, p 28 73°F Concentrated • 101 Gasoline E 28 73°F • 101 Methanol F 28 73°F • 301 Methanol F 28 73°F • 101 Phenol 5% p 28 73 F • 301 Phenol 5% p 28 73F • 101 Sodium Hydroxide 10% E 28 73°F • 301 Sodium Hydroxide 10% E 28 73°F

NOTE: Chemical resistance data for HYDEX 202 and 302 are similar to that of HYDEX 101 and 301.

49

HYDEX® 4101 Outstanding Electrical and Physical Properties Combined with Excellent Wear Resistance and Low Coefficient of Friction With No Center Line Porosity

PRODUCT DESCRIPTION PROPERTIES HYDEX® 4101 is a uniform high performance engineering Engineering Thermoplastic with a unique combination of thermoplastic made from GE plastics, VALOX* PBT­ properties: Polybutylene terephthalate. It is a semi-crystalline • Excellent Electrical Properties thermoplastic polyester. HYDEX® 4101 is characterized as • NO Porosity having good mechanical and electrical properties and does • Low Moisture Absorption not exhibit porosity in extruded form. • Good Impact • High Mechanical Strength and Rigidity APPLICATIONS • Good Abrasion Resistance and Lubricity HYDEX® 4101-Properties exceed PET in areas of: • Excellent Dimensional Stability • Good Machinability • Impact • Good Chemical Resistance • FDA Grades Available • Lower Moisture Absorption TYPICAL APPLICATIONS • Lubricity • Electrical/Electronic Applications • Better Temperature Properties Switches -Relays - Motor Parts Coil Bobbins • Small Engine Components - Rotor Shafts -Gears - Ignition Components • Material Handling -Gears - Bearing - Conveyor Wear Parts

PHYSICAL HYDEX 4101 PET PROPERTIES ASTM UNITS (unfilled} (unfilled} • Melting Point oc 247 249 • Tensile Break D638 QSi 8200 7,000 - 10,000 • Elongation D638 % 200 10 - 20 • ComQressive Strength D695 QSi 14,500 14,600 • Flexural Strength D790 QSi 16,700 18,000 • lzod Notched lmQact D256A ft-lb/in 1.0 0.5 • Coefficient of Linear Thermal ExQansion D696 10·6in/in/°C 60 65 • Heat Deflextion at 264 QSi D648 OF 130 100 • Water absorQtion 24-hr D570 % 0.08 0.1 • SQecific Gravity D792 - 1.31 1.44 • Hardness Rockwell M scale D785 - 117 95 • Flammability UL-94 - HB HB

SPECIFICATIONS AND TOLERANCES

Standard Sizes Length Plus Toi. Minus Toi. 1/4" to 1" dia. 5 & 10 ft. .002 .000 1-1/4" to 2" dia. 4 & 8 ft. .005 .000 2-1/4", 2-1/2" dia. 2 & 4 ft. .025 .000 3" to 6" dia. 2 & 4 ft. supplied over size

50

HYDEX®4101

ELECTRICAL HYDEX 4101 PROPERTIES ASTM UNITS (unfilled • Dielectric Strength, in Air, 125 mils D149 V/mil 400 • Dielectric Strength, in Oil, 62 mils D149 V/mil 590 • Dielectric Strength, in Oil, 125 mils D149 V/mil 400 • Dielectric Constant, 100 Hz D150 3.30 • Dielectric Constant, 1 mHz D150 3.10 • DissiQation Factor, 100 Hz D150 0.0020 • DissiQation Factor, 1 mHz D150 0.0200 • Hot Wire Ignition {PLC} UL746A PLC Code 3 • High Voltage Arc Track Rate {PLC} UL746A PLC Code 1 • High Voltage Arc Resistance UL746A PLC Code 2 • High AmQere Arc Ignition, Surface UL746A PLC Code 0

51

Kel-F®- PCTFE PROPERTIES

Excellent Properties: Seals: Lip, o-ring, v-rings and special construction seals are • Chemical Resistance fabricated for valves, compressors and pumps. • Dimensional Stability over Wide Temperature Range Films: , pharmaceutical packaging, optical • Cryogenic Applications recording, electroluminescent display panels to take • Liquid Oxygen Handling advantage of its excellent permeation resistance. • Gas Barrier Properties • Electrical Properties Gaskets: Pressure gaskets, diaphragms, liquid gauge shields are fabricated from Kel-F" 81 Plastic PCTFE for use Introduction in fluid handling systems.

Kel-F" 81 Plastic PCTFE is Bearings: Including sleeve and thrust, are fabricated where the homopolyer of high wear is a problem. chlorotrifluoroethylene. "Kel-F" is a registered trademark of 3M. This polymer structure imparts the properties that make Kel-F" 81 Plastic PCTFE a truly unique engineering thermoplastic. A complete family of powdered and pelletized polymers is covered by the product line. These products are designed for the production of high­ performance parts by the various conventional thermoplastic processing techniques currently used in the plastic industry.

Since Kel-F" 81 Plastic PCTFE is a versatile material whose properties may be modified over a wide range depending upon fabrication conditions, careful specification of pertinent properties for a given application is advisable.

Kel-F" 81 Plastic PCTFE offers the unique combination of physical and mechanical properties, nonflammability, high optical transparency, chemical resistance, near zero moisture absorption and excellent electrical properties that cannot be found in any other thermoplastic fluoropolymer with a useful temperature range of -240°C (-400°F) to +200°C (400°F).

Kel-F" 81 Plastic PCTFE is available in products which conform to ASTM D-1430, Type I, Grade I, Class B, and Class C.

Kel-F'" 81 Plastic PCTFE Molding Powders are suitable for processing into parts that meet the following government and industrial specifications:

MIL-P-46036 MIL-P-21470 (cancelled 1969) LP-385C AMS-3645 AMS-3650 FDA, Regulations under paragraph CRF 177.1380

Kel-F" 81 Plastic PCTFE, following 3M processing guidelines, also meets Marshall Space Flight Center Specifications NHB 8060.18 Test Method 13 & 14. Title of Publication: Flammability, Odor and Off Gasing Requirements & Test Procedures for Materials in Environments that Support Combustion.

Applications

Kel-F" 81 Plastic PCTFE is a versatile, tough, durable material with a wide variety of applications.

Valves: Valve seats, seals and stems of molded or machined Kel-F" 81 Plastic PCTFE have been used very successfully for many years.

52

Kel-F®- PCTFE PROPERTIES

GENERAL PHYSICAL & MECHANICAL PROPERTIES THERMAL PROPERTIES ASTM ASTM Property Method Units and Typical Values Property Method Units and Values

SI 0.15 W/(m.K) Zero Strength D-1430 200-420 seconds Time(ZS1) Thermal Conductivity C177 English 1.0 BTU in/hr ft2 °F

SI 210-215°C Melting Point, Tm OTA SI 900J/(kg.K) English 410-420°F Specific Heat DSC English .215 BTU/lb °F

Specific Gravity D-792 2.08-2.185 SI 1200 J/(kg.K) Heat of Fusion DSC SI 25°c 40MPa English 2.85 BTU/lb °F 125°c 4 MPa Tensile Strength D-638 @ Break SI 46MPa 126°c English 77°F 5725 psi 1.82 MPa 70°c Deflection 258°F 510 psi Temperature D 648 English 66 psi 258°F 264 psi 167°F SI 25°c 150% 125°c 400% Elongation @ Break D-638 Limiting Oxygen Index D2863 SI 100% English 77°F 150% 258°F 400% Vertical Burn Rating UL94 VE-0

SI 25°c 14x102 MPa Tensile Modulus D-638 Si 200°c English 77°F 207x103 psi Resistance to Heat, Continuous Service English 400°F SI 25°c 1350 MPa Compressive Modulus D-695 English 77°F 180x103 psi

SI 25°c 38MPa VAPOR PERMEABILITY CONSTANTS* D-695 Compressive Strength 1 English 77°F 55x102 psi VALUES OF P = 1 x 10 0cm3/cm2/mm/sec/cm Hg P Temperature SI 25°c 1250 MPa oc OF N2 He 02 CO2 H2 H2S H2O Flexural Modulus D-695 English 77°F 180x103 psi 0 32 - - 0.07 0.35 3.2 - -

25 77 0.05 21.7 0.40 1.4 9.8 - 1 SI 25°c 60MPa Flexural Strength D-695 50 122 0.30 - 1.40 2.4 24 0.35 10 English 77°F 8500 psi 75 167 0.91 - 5.70 15 - 2.0 28

SI 25°c 265 Kj/m 100 212 ------100 lzod Impact (notched) D-256 English 77°F 5 ft. lb/in •The true permeability constant (P) of "Kel-F 81" Plastic is expressed in cubic centimeters of 2 Hardness, Shore D D-2240 SI 75-80 gas under normal conditions traversing 1 cm of surface, 1 mm thick, per sec., per cm of mercury pressure

ELECTRICAL PROPERTIES

CRYOGENIC MECHANICAL PROPERTIES (a) Property ASTM Method Values {ASTM D-1430, TYPE L, GRADE I, CLASS C) Dielectric strength short time (volts/mil) D-149 500

Temperature °C D-495 360 Property (OF) Typical Values Arc resistance, seconds Volume resistivity, ohm cm'/cm Tensile:(b) 50% RHC 25°C (77°F) D-257 1.2 X 1018 Ultimate Strength, psi (MPa) -252 (-420) 29,000 (200) Surface Resistivity, ohm. -129 (-200) 21,800 (150) 50% RHC 25°C (77°F) D-257 101s + 25 (+ 75) 5,600 (39) Elongation, % -252 (-420) 5 -129 (-200) 9 +25 (+ 75) 140 Modulus of Elasticity psi(MPa) -252 (-420) 1,260 X 103 (8,680) Important Notice to Purchaser: All statements, technical information and -129 (-200) 800 X 103 (5,500) recommendations herein are based on tests we believe to be reliable, but the + 25 (+ 75) 220 X 103 (1,520) accuracy or completeness thereof is not guaranteed, and the following is made in lieu of all warranties, expressed or implied, including the implied warranties of Notched lzod Impact Strength(c) merchantability and fitness for purpose: Seller's and manufacturer's only ft.-lbs/in. Notch (J/M) -252 (-420) 7.6 (14) obligation shall be to replace such quantity of the product proved to be defective. -196 (-320) 7.1 (13) Before using, user shall determine the suitability of the product for its intended + 25 (+ 75) 7.6 (14) use, and user assumes all risk and liability whatsoever in connection therewith. NEITHER SELLER NOR MANUFACTURER SHALL BE LIABLE EITHER IN (a) R.E. Mowers: Cryogenic Properties of PCTFE, Air Force TORT OR IN CONTRACT FOR ANY LOSS OR DAMAGE, DIRECT, Contract No. AF04 (611)-6354 (1962) INCIDENTAL, OR CONSEQUENTIAL, ARISING OUT OF THE USE OF OR THE INABILITY TO USE THE PRODUCT. No statement or recommendation not (b) Amorphous polymer, 40% crystallinity contained herein shall have any force or effect unless in an agreement signed by (c) Amorphous polymer, 60% crystallinity officers of seller and manufacturer.

53

KYDEX®

AVAILABLE GRADES PHYSICAL PROPERTIES OF KYDEX 100 (Average Values - not intended for specification purposes) Kydex is offered in 3 different formulations for aircraft Property Test Method Value Specific Gravity ASTM D-792 1.35 interior applications. They are available from authorized Weight (lbs./sg. ft.), 1/8" No break Kydex sheet distributors. Custom sheet sizes are also MECHANICAL PROPERTIES Tensile Stress at Yield, psi ASTM D-638 6,000 available to minimize trim scrap. Modulus of Elasticity, psi 310,000 Elongation at Break, % > 100 Kydex® 100-The original, most widely known formulation Maximum Flexural Stress, psi ASTM-D-790 9,7000 of Kydex, field-proven for over 25 years. Standard gauges Modulus of Elasticity, psi 330,000 Compressive Strength, psi ASTM D-695 8,000 are available from .028" to .250". In all gauges, it meets FAR Bearing Strength, psi ASTM D-953 5,500 §25.853 (a). In .050" and greater, it meets FAR §25.853 (b). Shear Strength, psi ASTM D-732 4,500 Rockwell Hardness, R ASTM D-785 90 Over 200 developed colors are available. Five distinctive L 45 standard textures further expand design choices. The Durometer, Shore D ASTM D-2240 77 minimum order quantity for Kydex 100 is as low as one Taber Abrasion Resistance, wt. loss gms. ASTM D-1044 -0.015 sheet. CS-10 wheels, 1,000 gm/wheel, 100 Cycles Kydex® 657-This formulation offers <100/100 heat Impact Strength Charpy Unnotched ASTM D-256 release and is as easy to form as Kydex 100. In all gauges, (ft.lbs., 1/2" x 1" section) modified to 2" it meets FAR §25.853 (a) and (b). Standard gauges are 73° F span edgewise No break available from .040" to .187". Over 200 developed colors 32° F No break 0° F 25 and five standard textures are available. The minimum order -20° F 15 quantity is approximately 600 pounds. lzod Notched, ft.lbs.fin of notch 73° F ASTM D-256 10-15 Tensile Impact, ft. lbs.fin' ASTM D-1822 Kydex® 6565--The most flame retardant formulation of Long Specimen (Type L) Kydex sheet, Kydex 6565 meets FAR §25.853 (a-1), as well Short Specimen (Type S)

as FAR §25.853 (a) and (b). Like Kydex 657, it is as easy to 73° F 75 32° F 30 form as Kydex 100. Gauges and colors are available to 0° F 25

order. The minimum order quantity is approximately 600 -20° F 20 Falling Dart, ft. lbs. R&HP-24F

pounds. 3 lb. dart with 1/8" radius - (6" x 6" (Bruceton

samples with 1/2" engagement and staircase

clamped edges method) Kydex® sheet itself cannot be certified by the FAA, as it is (patterned surface impacted) not a finished part. However, to assist specifiers, Kleerdex 73° F >80

Company maintains a continually updated file of test data (indented

-no break) on these three products. Heat release test data are 32° F 60 developed for Kleerdex by Ohio State University, the 10 oo originator of the test method. -20° F 5.5 THERMAL PROPERTIES

Specific Heat, BTU/lb./°FR&H P-37 0.29

KYDEX® Characteristics Coefficient of Thermal Conductivity

(BTU/hr./°F/in./sq.ft.) ASTMC-177 1.1

RIGIDITY KYDEX® thermoplastic sheet is among the most Coefficient of Linear Thermal Expansion R&H P-4 rigid of thermoforming materials-up to 50% stronger than x-51° F 100° F 4.5 many of its competitors. This allows thinner gauge, lighter 60° F 4.2 weight parts with no compromise in strength. 20° F 4.0

-20°F 3.8

Deflection Temperature under Load,° F FORMABILITY KYDEX® sheet is unsurpassed in the 2° C/minute at: ASTM D-648 breadth of its forming range, extensibility and hot-tear 66 psi 177 strength. It's also extremely easy to work with once formed. 264 psi 165 Horizontal Burning Test ASTM D-635 FIRE RETARDANCY KYDEX® sheet is available in several Average Time of Burning, sec. 5 Average Extent of Burning, in. 0.8 formulations, each of which meet or exceed stringent flame Radient Panel ASTM E-162 4.7 and smoke retardancy requirements. Oxygen Index, % ASTM D-2863 35-40 Vertical Burning Test UL Subject 94 94V-0 IMPACT & ABRASION RESISTANCE For tensile ELECTRICAL PROPERTIES Dielectric Strength, volts/mil. ASTM D-149 430 strength, hardness, abrasion resistance and impact Dielectric Constant ASTM D-150 strength, few thermoplastic materials are tougher than 60 Hz 3.86 1,000 Hz 3.70 KYDEX® sheet. 1,000,000 Hz 3.44 Power Factor ASTM D-150 CHEMICAL RESISTANCE The KYDEX® family of 60 Hz 0.020 acrylic/PVC alloy sheet is more resistant to a,wider range of 1,000 Hz 0.020 1,000,000 Hz 0.027 concentrated chemicals than most other thermoplastics. Loss Factor ASTM D-150 60 Hz 0.077 TYPICAL APPLICATONS 1,000 Hz 0.074 1,000,000 Hz 0.093 • Air ducts • Lighting housings Arc Resistance, seconds ASTM D-495 80 MISCELLANEOUS • Armrests • Molding strips Water Absorption ASTM D-570 • Bulkhead laminates • Passenger service units 24 hrs. @ 23° C.% 0.06 • Escape slide packboards • Sidewall panels 7 days at 23° C,% 0.15 • Galley parts • Toilet shrouds Outdoor Weatherability Limited use only Staining-Removal of crayon, felt-tipped marker, and spray • Instrument Panels • Tray tables paint, using Anti-Vandal Spray Excellent • Lavatory floorpans • Window reveals Removal of Blaisdell crayon with Fantastick Good • Life vest shrouds

Kydex® is a registered trademark

54

KYDEX 6200® Kydex 6200 is specifically formulated to meet the fire safety needs of the mass transportation industry. FIRE RETARDANCY In independent laboratory testing, 1/8" thick Kydex 6200 sheet meets all Fire Safety Practices issued by the Urban Mass Transportation Administration. It shows less than a 35 flame spread index when tested in accordance with the ASTM E-162 radiant panel test conditions. The material showed no flaming, running or dripping. LOW SMOKE GENERATION Independent laboratory testing further shows that 1/8" thick Kydex 6200 sheet produces an optical density of less than 100 for smoke emission as measured at 90 seconds and less than 200 after 4 minutes when tested in accordance with the ASTM E-662 Smoke Density Test conditions.

DESIGN FLEXIBILITY Kydex 6200 can be easily thermoformed or fabricated into almost any desired two- or three-dimensional shape using standard equipment and techniques (see other side for a list of typical applications). The material is offered in a variety of attractive colors and several textured surface finishes, making it possible to satisfy the requirements for virtually any transportation system's decor.

LOW MAINTENANCE Graffiti problems? Markings in lipstick, ballpoint pen, felt pen and spray paint are easy to remove from Kydex 6200. The material also resists attack and staining from a variety of chemicals and foodstuffs.

Kydex 6200 Transportation - grade Thermoformable Sheet-TEST RESULTS Physical Properties Test Method Values Specific Gravity ASTM D-72 1.50

Mechanical Properties

Tensile Strength at Yield (psi) ASTM D-638 6,000

Modulus of Elasticity (psi) 360,000

Maximum Flexural Stress (psi) ASTM D-790 10,500

Modulus of Elasticity (psi) 360,000

Hardness, Rockwell L ASTM D-785 67

Impact Strength ASTM D-3763 "Dynatup" (in-lbs)

Energy to Max 180

Total Energy 340

Thermal Properties

DTUL@264 psi annealed ASTM D-648 155-160°F

Flammability Properties ASTM E-662

NBS Smoke Chamber [email protected] min. ::;;200 Ds@ 1.5 min. ::;;100

Radiant Panel Flame Spread Index ASTM E-162 ls<35 Vertical Burn Test UL Subject 94 V-0 Motor Vehicle Safety Standard 302 pass

Values are based upon nominal 0.125" thickness in flat sheet. Not intended for specification purposes.

Kydex® is a registered trademark

55

KYNAR®

Kynar® is a high molecular weight ther­ General Physical and Mechanical moplastic polymer of vinylidene fluoride Properties of Kynar® PVDF ASTM which is used extensively in the chemical Prooertv Method Values and Units processing industry because of its unique SI 1.75-1.78 g/ml Specific Gravity D-792 English 109.3-111.3 ib./ft.' combination of properties. Kynar® posses­ SI 0.56-0.57 ml/g ses excellent corrosion and chemical re­ Specific Volume D-792 English 15.5-15.8 in'/lb Refractive Index D-542 SI 1.42 nl:, sistance, is a tough and durable material, Si 156-168°C and is easily fabricated into many finished Melting Point D-3418 English 312-334°F Water Absorption D-570 Si 0.04-0.06% parts required by the chemical processing SI 25°C 36-51 MPa Si 100°c 19-23 MPa industry. Tensile Strength @ Yield D-638 English 77°F 5200-7400 psi English 212°F 2700-3400 psi SI 25°C 36-52 MPa Kynar® for CPI Systems SI 100°c 19-23 MPa Tensile Strength @ Break D-638 English 77°F 5200-7500 psi Kynar® is specified for CPI systems for these English 212°F 2700-3400 psi reasons: SI 25°C (77°F) 25-500% Elongation @ Break D-638 SI 100° C (212°F) 400-600% • Mechanically strong and tough SI 1340-1515 MPa Tensile Modulus D-638 English 194-219 x10' psi • Thermally stable SI 1100-1730 MPa • Resistant to most chemicals and solvents Stiffness in Flex D-747 English 160-250 X 10' psi SI 59-75 MPa • Stable to UV and the effects of weather Flexural Strength D-790 English 8.6-10.8 X 10' psi SI 1200-1800 MPa • Self-extinguishing Flexural Modulus D-790 English 175-260 X 10' psi SI 25°C 55-69 MPa Applications Compressive Strength D-695 English 77°F 8000-10,000 psi SI 25°C 160-530 kJ/m Typical examples of fabricated Kynar® lzod Impact (notched) D-256 English 77°F 3.0-10.3 ft.lb.fin. SI 25°C 1710-3100 kJ/m include: lzod Impact (unnotched) D-256 English 77°F 32-58 ft.lb.fin. • Process vessels and fluid handling equip­ Hardness, Shore D-2240 SI 70-80 Hardness, Knoop Tukon SI 9.4-9.6 ment to handle mineral acids, halogens, Coefficient of Sliding 0.14-0.17 oxidants, chlorinated organics, bleach­ Friction to Steel SI SI 4.01/um ing solutions and most aromatic and Sand Abrasion D-968 English 1021-0.0011' aliphatic hydrocarbons. Wheel Tabor Abrasion CS-17 SI 7.0-9.0 mg/1000 cycles • Film of high temperature and chemical 1000 g resistance for solution-metering pumps, and for brick-lined towers. General Thermal Properties of • Rod and sheeting resistant to chemicals Kynar PVDF used in the paper manufacturing industry. ASTM • Sheeting for plating and etching tanks, Prooertv Method Values and Units SI 0.100-0.126 W/K.m and for water treatment applications re­ Thermal Conductivity C-177 English 0.70-0.871 BTU in./hrft' °F quiring resistance to sulfuric acid. SI 1.26-1.42 kJ/kg.K Specific Heat DSC English 0.30-0.34 BTU/Ib./°F • Chlorine-resistant spray headers. SI 25-60°C 7.9-14.1 x 10-S;oc • Packing support trays. Coefficient of Linear Expansion D-696 English 77-140°F 4.4-7.9 x 10-S;of Limiting Oxygen Index (LOI) D-2863 SI 44% • Instrumentation and controls equipment. SI 455 kPa 80-90°C SI 1820 kPa 112-140°C • Linings: laminated (wet lay-up and Deflection Temperature D-648 English 264 psi 176-194°F sheet) and solid or glass-backed sheet. English 66 psi 234-284° F SI -62°C • Mist eliminators. Low Temperature Embrittlement D-746 English -80°F SI In air: 375°C • Monofilament. SI In nitrogen: 410°C Thermal Decomposition TGA English In air: 709° F • Motionless mixers. Enolish In nitrogen: 770° F D-568 Self-extinguishing • Pipeand Fittings:solid Kynar®,linedsteel, Burning Rate D-635 Non-dripping FRP/Kynar® laminate. • Pumps: centrifugal, metering, plunger, Product Availability rotary, sump. Rod- 1/8" to 7" in diameter • Stock Shapes: solid and porous rod, Sheet and Slab-0.030" to 4" thick sheet and tubing. Also tube fittings. Glass Backed Sheet-.040" - .125" thick Film-0.003" to 0.020" thick

56

KYNAR®

Product Safety Stability to Effects of Weather and A number of studies relating to the safe use of Ultraviolet Radiation Kynar® polyvinylidene fluoride havebeen made over One of the outstanding properties of Kynar®PVDF the last decade. A brief summary of these studies is is its stability to weather. The combination of low given in the following paragraphs: moisture absorption, high resistance to chemical Toxicity and Biological Studies of Kynar® PVDF and mechanical stresses, and stability to the effects Kynar®PVDFmaybeused in articles intended for of ultraviolet radiation make the polymer suitable repeated contact with food in accordance with for applications requiring long life under severe extraction and washing conditions as prescribed in atmospheric conditions. Table 1 shows that the Code of Federal Reg1,.1lations, Title 21, Food & mechanical properties of Kynar® fi Im are maintained Drugs, Chapter F, Pl. 121.2593 throughout many years of outdoor exposure, Clear Kynar®PVDFis also chemicallyacceptable foruse films, exposed to the sun at a 45° angle South, in processing or storage areas for contact with meat retained their tensile strengths over a 17-year period. or poultry food products prepared under Federal During the first few months of exposure when nor­ inspection according to the U.S. Department of mal crystallization takes place, the percent of elon­ Agriculture (USDA). gation at break decreases to a level which remains Kynar®PVDF also complies with the criteria in"3-A essentially constant with time. In addition, the wea­ Sanitary Standards for Multiple-Use Plastic Mate­ thered films remain flexible and capable of being rials Used as Product Contact Surfaces for Dairy bent 180° without cracking. Equipment. Serial No. 2000." No adverse toxicological or biological response Table 1. Stress/Strain Properties of has been found forKynar®PVDF when injected into, 0.204 mm (0.008") Weathered Kynar® PVDF Film or placed in contact with, test animals under con­ Determined by ASTM Method D-882

trolled conditions. Tests include: acute oral toxicity, Before After Outdoor Property Exposure Exposure (17yrs.) inhalation, implantation, tissue culture, systemic, SI 47.5 MPa 59.0 MPa and sub-acute toxicity types. Tensile Strength English 6900 psi 8500 psi Burning Studies SI 46% 10% In accordance with ASTM D-2863, Kynar® PVDF Elongation at Break English has a (LOI) limiting oxygen index of 44, i.e. 44%

oxygen is needed for the polymer to support com­ bustion. Underwriters' Laboratories gives Kynar® Resistance to Nuclear Radiation PVDF a fire rating of 94 V-0. Sheets of Kynar®coated The resistance of Kynar® PVDF to nuclear radia­ metal exhibited zero flame spread when tested in tion is excellent. Upon exposure to 1000 megarads 60 accordance with the ASTM E-84-70 tunnel test. (Gamma radiation Co ) at 50° C (122° F) and high vacuum (10-6 Torr), the original tensile strength is Flexural Creep essentially retained. The impact strength and elon­ The long-term resistance of Kynar® PVDF to flex­ gation are slightly reduced due to crosslinking. ural creep at elevated temperature is shown in Fig­ The stability to effects of radiation, combined with ure1.These data indicate Kynar®PVDF to be suitable the chemical resistance of Kynar®PVDF, has resulted for many applications where load-bearing charac­ in successful use of components in plutonium recla­ teristics are important. mation plants. Figure 1. Flexural Creep/Time and Temperature Parts fabricated from Kynar® PVDF can be effec­ tively crosslinked by high energy radiation sources to achieve unique properties. Examples of Kynar®

60 PVDFfabricated products utilizing such technology are heat-shrinkable tubing and insulated wire capa­ -J?. 50 ble of withstanding high temperatures. r:: 0 40 lllJ :g 7 A! >a (52 :Jp!1) C!T Important Properties of Kynar® PVDF .$! 30 )0 ·1 ai 1 Pa (A 54 t si 9 • Mechanical strength and toughness Cl - ,n • a o II 0 t-l a • High abrasion resistance 20 C ( f A F) A >a (1 / 2 P' i) ,o • High thermal stability 10 i) ,O C (IL r • High dielectric strength 1 " A >a (17 2P • Resistance to most chemicals and solvents 10 100 1000 Time, hrs. • Resistance to ultraviolet and nuclear radiation ·• Resistance to weathering

57

LAMINATED PLASTICS - THERMOSET

The fundamental difference between laminated and Grade X - For general use. Paper base, furnished in molded phenolics is in the nature of the filler used. The resin Natural, Chocolate Brown, and Black with natural core. is basically the same although in the molded group it has Thickness from .015 in. and up. Punches up to 1/32 in. cold been developed along the lines of speed of cure, a and to greater thicknesses when heated. Machines readily. characteristic which is not so important in the laminated industry. Grade XX - For electrical applications requiring low moisture absorption. Paper base in natural or black. Molded phenolics are powders or comparatively small Thickness from .015 in. up. Low moisture absorption. pieces impregnated with resin. Laminated uses sheets of paper, linen, canvas, silk, cotton, nylon, glass, asbestos, Grade XXX - For extremely low moisture absorption and and other substrates impregnated and dried in a continuous high dielectric strength. Paper base, natural or black. operation so the original interlacing and length of fiber are Thickness from 1/32 in. up. not destroyed. Grade XP - For punching operations, electrical These sheets are piled flat in large hydraulic presses on applications. Paper base, natural or chocolate brown with heated platens and pressed during the cure to various natural core, black with natural core, black with black core, thicknesses. Rods and tubes are made in standard sizes by chocolate brown with shiny or satin finish. Punches and rolling on mandrels. shears cold up to 3/32 in. In thicker sections depending on the design of the die and the temperature of the material. The trade has standardized on grades which, by variation of the filler and treatment, have different qualities. Like Grade C and CE - For exceptional structural strength. molded phenolics, if one characteristic is to be emphasized Coarse weave cotton. Natural or black. Punches readily. others may have to be minimized. Highly resilient insulation. Structural qualities recommend it where high tensile and transverse strength are required in Although laminated may be molded to many shapes, the connection with good insulating properties. E refers to lack of flow due to the interlaced fibers requires the cutting electrical grades. of forms of graduated shape and their careful assembling in the proper order and quantity. Grade L and LE - For fine machining. Linen base, natural or black. Thickness from .015 in. up. Not usually over 1/8 in. The strength, flexibility, and imperviousness to oil and E refers to electrical grades. moisture are the outstanding qualities that suit this material for its wide use as silent gears. These are hobbed from Grades A and M - Asbestos paper-based grades. More molded or cut blanks. resistant to heat and flame than cellulosic-based grades. Not recommended for primary insulation in applications In high dielectric strength, high insulation resistance, and involving commercial power frequencies at voltages over great strength in thin sections recommend it for simple 250. A is based on asbestos paper; M is based on punchings. asbestos fabric and is stronger and more heat-resistant. It is widely used in the plating industry in place of wood for Grade G-3 - Glass-based. Has high impact and flexural and carriers. The rayon industry uses it not only strength; good electrical properties under dry conditions; because it resists alkaline reagents but because of its good dielectric strength perpendicular to laminates; and lightness and strength. good dimensional stability. Used for structural parts requiring good electrical properties and on equipment Recently the decoration of walls, table tops, and counters operating at relatively high temperatures. has absorbed an increasing amount of this material. It can be faced in the molding process with printed sheets to Grade N-1 - Nylon fabric based. Excellent electrical simulate marble, wood, or any original design for highly properties under high humidity. Good impact strength, but decorative results. Its resistance to acids, moisture, and subject to flow or creep at temperature higher than normal. wear makes it an ideal finish. Different manufacturers produce minor variations of the Manufacturers of laminated material of this type affiliated above general classifications to suit their individual with the National Electrical Manufacturers' Association have customers' requirements and in some cases have prefixed adopted a common nomenclature in describing their sheets or suffixed the above symbols with symbols of their own. as follows:

58

LAMINATED PLASTICS - THERMOSET

NEMAor Norplex Oak Industry Color Grade Grade Designation Descriotions NP606* - N,B Phenolic-paper: low resin content machinina arade. NP610 X N,B,C Phenolic-paper: toolinQ and hot punchinQ stock. UL listed. NP611 XP N,B,C Phenolic-paper: hot punchina stock. UL listed. NP612 XPC N,B Phenolic-cotton linter paper: room temperature punchinQ stock. UL listed. NP614 - - Phenolic-paper: vulcanized fiber covers on both sides. NP615 - - Phenolic-cotton linter paper: melamine-pa12er covers on both sides. NP625 XPC N,B,C Phenolic-cotton linter paper: plasticized warm punchina stock. NP630 xx,xxx N,B Phenolic-cotton linter paper: excellent electrical properties. L-P 513, type PBE. UL listed. NP631 Phenolic-cotton linter paper: hot punching stock with excellent punching XXXP N,B characteristics. L-P-513, type PBE-P. UL listed. N,B Phenolic-cotton linter paper: plasticized room temperature punching stock NP632 XXXPC with excellent electrical properties. L-P-513, tyQe PBE-P. UL listed. - - Phenolic-paper/glass fabric: XP core with phenolic-glass covers on both NP634 sides for increased flexural strenQth. - - Phenolic-paper: low cost material with high compressive strength and low NP639 moisture absorotion. NP648 XP B Phenolic-paper: post-formina material. UL listed. NP660 XP (economv) N,B Phenolic-paper: economv punchina stock. NP664 - N,B Phenolic-paper: low cost room temperature punchina stock. N,B Phenolic-cotton linter paper: good electrical, mechanical and punching NP680 XXP characteristics. NP691 FR-1 N,B Phenolic-cotton linter paper: room temperature punching stock. Flame retardant. UL listed. NP692 FR-2 N Phenolic-cotton linter paper: hot punching stock. Flame retardant. UL listed. NP695 XXXP N,B Phenolic-cotton linter paper: L-P-513, type PBE-P. UL listed. NP697 XP N,B Phenolic-paper: hot punchina arade. UL listed. NP101 N-1 Phenolic-nylon fabric: good impact strength and electrical properties under high N humidity conditions. NP310 c- N,B Phenolic-canvas: intended for structural aPPlications. MIL-P-15035, type FBM. NP310E CE N,B Phenolic-canvas: suited for electrical applications. MIL-P-15035, type FBG. UL listed. NP313 CMD N,B Phenolic canvas: molybdenum disulfide added as a solid lubricant. NP315 CYB B Phenolic-canvas: powdered Graphite added as a solid lubricant. NP317 - - Phenolic-canvas: hiah temperature arade. NP318 CF N,B Phenolic-canvas: intended for post-forminQ aQQlications. L-P-511, MIL-P-8655A NP319 - - Phenolic-canvas: bleached fabric, powdered araohite added as a solid lubricant. NP320 L Phenolic-linen: light weight cotton fabric, 4 oz. maximum, MIL-P-15035, type N,B FBI NP320E LE N,B Phenolic-linen: light weight cotton fabric, 4 oz. maximum, MIL-P-15035, type FBE. NP321 L (vanes) N Phenolic-linen: for compressor and air motor vanes. NP322 - - Phenolic-linen: molybdenum disulfide added as a solid lubricant. NP325 LYB B Phenolic-linen: powdered araPhite added as a solid lubricant. NP329 MLE Melamine-linen: provides better arc resistance than phenolic-linen or phenolic- N canvas arades. NP342 CFW N Phenolic-canvas: fine weave fabric for Qood machininQ properties. NP347 CHTMD Phenolic-canvas: high temperature. Molybdenum disulfide added as a solid N lubricant. NP504 G-3 N Phenolic-alass fabric: hiah temperature. NP509 G-5, G-9 N Melamine alass fabric: MIL-P-15037, tvpe GMG and GME. UL listed. NP510A FR-4 N Epoxv-alass fabric: commercial epoxy-glass fabric. MIL-P-18177, !}'Qe GEE. NP511 G-11 N Epoxv-alass fabric: hiah temperature. MIL-P-18177, tvPe GEB. UL listed. ED130 FR-4 N Epoxy-glass fabric: meets MIL-P-18177, type GEE and MIL-P-13949G. UL listed. NP841 - - Phenolic-glass fabric: Kocite® added to the resin to give the laminate controlled conductivity. NP581 - - Phenolic-glass: high strength glass with high temperature resin.

59

PHYSICAL PROPERTIES OF LAMINATED PLASTICS - THERMOSET

Norplex/Oak Grade NP101 NP310 NP310E NP342 NP345 NP317 NP318 NP320 NP320E NP610 NP611 NP612 NP623 NP625 NP630 NP631 NP632 NEMA Grade N-1 C CE C CE C CF L LE X XP XPC XP XPC XXX XXXP XXXPC Military or Federal Spec 15047 15035 15035 15035 15035 511 15035 15035 509 509 509 509 509 613 613 613 Type NPG FBM FBG FBM - FBM - FBI FBE - - - - - PBE PB!=-'.P PBE-P UL Listed - - E37002 ------E37002 E37002 E37002 - - E37002 E37002 E37002 Colors NA NA,BK NA,BK NA NA NA NA, BK NA, BK NA,BK NA, BK, CH NA, BK, CH NA,BK NA, BK, CH NA, BK, CH NA,BK NA,BK NA,BK Thickness Range 0.18- .031- .031- .031- .062- 0.31- .031- .010- 0.10- .016- .010- .010- .010- .010- .010- .015- .012- 4.000 4.000 4.000 4.000 4.000 1.125 .3120 4.000 4.0000 4.000 2.000 1.000 1.000 1.000 4.000 1.000 5.000 Weiaht Factor 6.22 7.20 7.20 7.20 7.20 7.20 7.20 7.20 7.20 7.26 7.00 7.10 7.10 7.10 7.00 7.00 7.00 General Phvsical Properties* Specific Gravity 1.25 1.37 1.37 1.35 1.34 1.35 1.32 1.34 1.34 1.40 1.35 1.38 1.39 1.39 1.38 1.38 1.41 Rockwell Hardness ± 10 90 100 100 100 100 102 90 100 100 105 100 84 90 85 101 105 80 Moisture Absorption(%) Cond E-1/105 + D-24/23 0.30 2.50 2.00 1.80 2.00 2.10 4.20 2.30 1.90 1.80 1.50 3.20 1.35 1.60 0.57 1.00 0.40 Flexural Strength (psi)-LW 14,000 20,000 18,000 25,000 22,200 23,000 19,000 24,500 22,000 34,000 29,600 19,300 24,500 19,000 24,000 16,000 18,500 cw 11,000 18,000 16,000 22,700 16,100 19,500 16,000 18,500 16,000 28,000 22,500 17,600 22,400 17,000 19,000 13,200 15,000 Modulus of Elasticity in Flexure (kpsi)-LW 700 1,600 1,600 17,000 1,600 1,500 1,100 1,700 1,600 1,900 1,200 1,000 1,100 1,000 1,300 1,100 1,000 cw 550 1,500 1,500 1,300 1,200 1,200 900 1,300 1,200 1,400 900 850 900 850 1050 900 750 Tensil Strength (psi)-LW 8,000 12,000 11,000 12,700 11,000 11,000 9,000 14,000 13,000 20,000 18,000 12,500 12,800 12,400 17,500 15,000 12,800 cw 8,000 9,700 9,000 10,900 6,000 9,500 6,500 10,000 9,000 16,000 13,500 8,400 10,800 10,400 13,000 12,000 9,700 Compressive Strenath (psi) 25,000 38,000 36,000 35,000 37,000 40,000 30,000 38,000 36,000 35,000 45,000 27,000 31,500 29,500 3,500 3,200 2,700 lzod Impact Strength {ft/lbs/in) Cond E-48/50 LW 3.40 2.30 2.10 1.60 1.90 2.60 2.50 1.70 1.35 0.82 0.70 0.76 0.80 0.75 0.75 0.65 0.62 Cond E-48/50 CW 2.70 2.00 1.90 1.40 1.40 2.20 2.00 1.35 1.10 0.76 0.60 0.66 0.75 0.70 0.65 0.60 0.57 Bond Strenath (lbs) 1,800 2,000 1,900 1,900 2,200 2,000 1,800 2,000 1,900 1,000 1,100 1,400 1,300 1,100 1,200 1,100 1,000 Shear Strenqth (psi) 14,000 14,000 14,000 14,000 13,500 13,000 12,000 13,500 13,500 15,000 12,200 9,500 1,200 1,500 12,800 1,150 1,000 Thermal & Electrical Properties Maximum Operating Temperature (°C) 105 125 125 125 130 150 125 125 125 130 130 130 130 130 140 125 125 Coefficient of Thermal

(in/in/°Cx1 5 o- ) Expansion x-axis 9.5 2.0 2.0 2.0 2.0 1.8 N/A 1.8 1.8 1.3 1.3 1.5 1.5 1.5 1.5 1.6 1.7 y-axis 12.0 2.2 2.2 2.2 2.2 2.0 N/A 1.9 1.9 1.7 1.7 1.9 1.9 1.9 1.9 2.0 1.9 Flammability 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94HB

Dielectric Breakdown (kV) CondA 65 55 55 40 55 40 65 45 50 40 50 55 60 60 55 60 65 Cond D-48/50 45 3 3 3 5 3 4 2 5 N/A 4 10 7 7 15 15 15 Electric Strength (V/mil) CondA 650 500 550 550 600 625 480 575 625 600 600 700 700 700 700 750 750 Cond D-48/50 500 250 300 300 350 550 350 450 500 N/A N/A N/A N/A N/A 600 600 600 Permitivity Cond D-24/23 3.75 N/A N/A N/A N/A 5.70 N/A 5.80 5.50 N/A N/A 5.50 6.05 6.05 5.10 4.80 4.80 Dissipation Factor Cond D-24/23 0.035 N/A N/A N/A N/A 0.050 N/A 0.070 0.065 N/A N/A 0.060 0.060 0.060 0.035 0.035 0.035 Arc Resistance (sec) 17 15 15 15 15 15 10 15 15 90 75 110 90 90 110 124 120 .. . . * All testing performed at CondIt1on A, unless otherwise specIf1ed. See notes on page 18.

60

PHYSICAL PROPERTIES OF LAMINATED PLASTICS- THERMOSET

Norolex/Oak Grade NP648 NP660 NP664 NP680 NP691 NP692 NP695 NP696 NP697 NP842 NP424 NP504 NP509 NP510A NP511 NP581 G-10 G-10FR G-10CR NEMA Grade XP XP XPC XP FR-1 FR-2 XXXP XXXP XP - CEM-1 G-3 G-9 FR-4 G-11 G-3 G-10 FR-4 G-10 Military or Federal Spec ------15037 18177 18177 25515 18177 13949 - Tvpe ------PBE-P PEP-P - - - - GME GEE GEB 46040 GEE GF - UL Listed E37002 - - - E37002 E37002 E37002 E37002 - - E37002 - E37002 - E37002 - E37002 E37002 - Colors BK NA,BK NA, BK NA,BK NA,BK NA NA,BK NA NA, BK BK TN,BL NA NA NA NA NA NA NA, BL, BK NA Thickness Range .031- .016- 0.31- .010- .031- .031- .017- .031- 0.10- 0.31- .031- .015- .008- .030- .012- .020- .012- .007- .012- .2500 1.125 1.000 1.125 1.000 1.125 .3120 .2500 .5000 .5000 .2500 4.000 4.000 4.000 4.000 1.000 4.000 4.000 4.000 Weiqht Factor 7.00 7.00 7.65 7.78 7.10 7.78 7.00 7.00 7.10 7.30 N/A 10.00 10.25 10.00 10.00 10.00 9.35 10.00 10.00 General Phvsical Properties* Specific Gravitv 1.34 1.35 1.37 1.39 1.33 1.40 1.31 1.30 1.35 1.37 N/A 1.80 1.85 1.85 1.80 1.85 1.80 1.80 1.85 Rockwell Hardness ± 10 105 100 90 94 85 100 95 110 100 100 102 110 115 115 112 115 110 110 110 Moisture absorption(%)

Cond E-1/105 + D-24/23 2.67 3.50 5.50 1.30 1.20 0.60 0.39 0.40 2.50 1.00 0.15 2.94 0.60 0.10 0.20 0.20 0.10 0.15 0.15 Flexural Strength (psi)-LW 16,200 33,000 26,000 26,400 16,000 17,000 22,200 25,000 28,000 21,000 48,000 40,500 61,600 65,000 80,000 80,000 75,000 70,000 73,000 cw 12,100 30,000 24,000 21,600 13,000 15,000 19,200 23,000 22,800 15,000 40,000 36,000 51,100 52,000 70,000 70,000 65,000 60,000 62,000 Modulus of Elasticity

in Flexure (kpsi)-LW 1,600 1,900 1,200 1,000 1,000 900 1,000 1,100 1,050 1,000 2,500 1,800 2,000 2,900 3,000 3,600 2,700 2,700 2,700 cw 800 1,400 1,000 900 900 800 800 900 950 900 2,100 1,400 1,700 2,600 2,700 3,200 2,400 2,400 2,400 Tensil Strength (psi)-LW 10,000 20,000 12,500 17,000 12,000 11,200 12,500 13,000 14,000. 20,000 N/A 42,000 44,000 40,000 43,000 50,000 45,000 45,000 45,000 cw 8,000 16,000 12,500 13,500 9,000 9,200 9,500 10,000 10,300 16,000 34,100 34,000 34,000 32,000 37,000 45,000 38,000 38,000 38,000 Compressive Strenqth (psi) 32,000 49,000 30,000 38,000 25,000 24,600 30,000 35,000 35,000 35,000 50,000 76,000 70,000 66,000 63,000 65,000 65,000 65,000 49,000 lzod Impact Strength (ft/lbs/in)

Cond E-48/50 LW 1.00 0.75 0.67 0.56 0.90 0.55 0.62 0.75 0.72 0.55 1.7 12.0 12.5 7.9 12.0 11.5 14.0 14.0 12.3 Cond E-48/50 CW 0.75 0.70 0.62 0.49 0.80 0.47 0.52 0.70 0.65 0.45 1.3 11.0 8.5 7.3 9.0 9.0 12.0 12.0 8.7 Bond Strenqth (lbs) 1,800 1,100 1,100 1,300 1,200 1,200 1,400 1,300 1,200 1,200 1,400 1,600 1,900 2,300 2,200 1,800 2,200 2,200 2,200 Shear Strenath (psi) 13,500 14,000 11,000 11,000 12,000 10,800 11,000 12,000 11,300 11,200 12,500 18,000 18,000 21,500 22,000 27,000 22,000 22,000 22,000 Thermal & Electrical Properties Maximum Operating

Temperature (°C) 130 130 130 130 105 105 125 125 130 150 130 175 140 140 180 240 140 140 140 Coefficient of Thermal

(in/in/°Cx10·5 ) Expansion x-axis 2.2 1.3 1.8 1.6 1.6 1.6 1.3 1.4 1.4 1.0 1.3 1.5 1.5 1.0 1.1 1.5 1.0 1.0 0.9 y-axis 2.4 1.7 2.0 2.0 2.0 2.0 1.7 1.8 1.8 1.2 1.6 1.8 1.8 1.3 1.3 1.8 1.3 1.2 1.1 Flammability 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94HB 94V-O 94HB 94V-1 94V-O 94HB 94HB 94HB 94V-O 94HB Dielectric Breakdown (kV)

CondA 50 47 60 55 55 60 60 60 60 N/A 60 70 65 66 60 35 60 65 63 Cond D-48/50 10 10 10 12 4 9 20 50 10 N/A 40 9 55 65 55 10 50 54 50 Electric Strength (V/mil)

CondA 600 500 500 750 500 675 825 800 750 N/A 675 375 450 800 900 700 800 800 800 Cond D-48/50 400 300 300 500 300 450 600 650 500 N/A 400 200 400 750 800 550 750 750 750 Permittivity

Cond D-24/23 5.60 5.45 N/A 5.00 5.20 4.75 4.75 4.60 5.20 N/A 4.60 N/A 7.03 4.80 4.80 N/A 4.80 4.80 4.80 Dissipation Factor Cond D-24/23 0.047 0.045 N/A 0.040 0.065 0.048 0.030 0.025 0.060 N/A N/A N/A 0.015 0.032 0.020 N/A 0.025 0.025 0.024 Arc Resistance (sec) 60 60 110 100 100 75 90 75 75 N/A 121 100 185 130 120 100 100 100 100

Comparative Tracking Index 150 150 180 180 240 270 500 190 150 N/A

61

NYLATRON® - GS & GSM, MC 901 & 907

Nylatron® GS Nylatron® GSM & MC 901 + MC 907 Nylatron® GS nylon is a nylon and molybdenum disulphide MonoCast and Nylatron® GSM nylon are produced by composition designed to improve the mechanical and direct polymerization of monomer to shapes of nylon thermal properties of type 6/6 nylon, while maintaining its polymer, within a mold at atmospheric pressure. basic electrical and chemical characteristics. MC® 901, which is heat stabilized, is the basic form of The addition of finely divided particles of MoS2 solid MonoCast nylon, and is blue in color. Nylatron® GSM is lubricant adds extra lubricity to nylon, permitting Nylatron® grey-black, and contains finely divided particles of GS parts to operate with little or no lubrication. This makes molybdenum disulphide solid lubricant dispersed Nylatron® GS nylon especially suited to applications where throughout. While both formulations have similar lubrication is impractical,contaminating or difficult to mechanical, chemical and electrical properties, the maintain. molybdenum disulphide provides extra surface lubricity in In addition to the advantages offered by nylon's non­ Nylatron® nylon, without sacrificing any of the premium galling and non-scratching characteristics, sound properties of the basic material. dampening qualities, insulating properties, resistance to oils, The MonoCast process has made the premium properties greases, most alkalis, solvents and organic acids, Nylatron® and performance of MC and Nylatron® nylons available to GS nylon also provides these "plus" properties: many applications where large part size once necessitated Greater Wear Resistance-Offering longer wear in many the use of metal exclusively. Now benefits of light weight applications-frequently performing satisfactorily where (MC and Nylatron® weigh only 1/7 as much as bronze), unfilled nylon parts fail. reduced lubrication requirements, corrosion and impact Lower Surface Friction-The internal lubricant, resistance, sound dampening, elimination of pilferage (unlike molybdenum disulphide, means a lower coefficient of friction bronze, MC and Nylatron® have no scrap value) and non­ for superior performance when lubrication is undesirable or galling characteristics can be applied to any part within impractical. design parameters, without regard to size. Polymer has cast Higher Strength and Greater Rigidity-Tensile and parts weighing up to 1200 pounds-a steel casting of the compressive strengths are increased and the elastic same size would weigh more than four tons. modulus is increased more than 40%. Nylatron® GS parts The machinability of MonoCast and Nylatron® is also an are more resistant to deformation under load. important factor.Both materials can be machined on Superior Heat Resistance-Parts resist distortion at standard metalworking equipment to produce long-wearing, temperatures 50°F higher than unfilled type 6/6 nylon; tough service parts. therefore, higher applied loads are possible as temperatures Both MonoCast and Nylatron® nylons have long records of increase. outstanding service as a multitude of parts in such diverse fields as paper and textiles, construction, mining, Improved Dimensional Stability-With a linear coefficient metalworking and material handling. of thermal expansion less than that of nylon 101, Nylatron® GS parts maintain better fits and clearances, have less *MC907 is a natural colored unfilled cast type 6 nylon. tendency to seize as bearings. PROPERTIES PROPERTIES • Wear resistance • High fatigue resistance • Excellent wear resistance • Low friction • Easy machining • Low surface friction • High tensile strength • Corrosion resistant • High strength and rigidity • Excellent impact resistance • Lightweight • Superior heat resistance • High heat distortion temperature • Improved dimensional stability • Excellent vibration, peening resistance TYPICAL APPLICATIONS TYPICAL APPLICATIONS • Bearings • Busings • Valve seats • Washers, Seals • • Bearings • Bushings • Valve seats • Thrust washers Cams, Gears• Sleeves, Wheels• Guides• Tooling fixtures• • Wear surfaces • Rollers • Gears • Sleeves • Forming dies Insulators • Wear parts • Tooling fixtures AVAILABILITIES STANDARD LENGTHS & TOLERANCES Rod Rod-4 & 8 ft., to 1" (±.001) 1fa" Diameter: 1// increments from 2" to 71/2 " plus 21/a" and 11/s'' to 2" (+.005 to -.000) 1 27/8" ; 1" increments from 8" to 12" plus 8%", 9 // and 9%" Sheet- Slab size 12" x 48" and 24" x 48" Length: 21/s'' to 5%"-2 ft.; 6" and over-1 ft. Thickness 1/16", 3/'22.", 1fa" (±.005) Sheet 3/16" and up (+.025 to -.000) 5 Thickness: 1// increments to 4" plus 3/16", %", / 8" Width 12" (±.250); 24" (+.500 to - .000) Size: 24" x 48", 12" x 12" and 24" x 24" available 48" x 48" Available up to 144" Length Tube OD: 2" to 7" at 1// increments 1 71;2 to 12" at // increments 12" to 18" at 1" increments ID: 1" to 16" in various increments available in 13" and 26" lengths STANDARD TOLERANCES Rod Diameter: 2" to 27/a''-+.015-.000; 3" to 5"-+.187-.000; 51// and UP-+,250-.000 Sheet Thickness + .025 - .000 Width ±.500

62

NYLATRON® NS AND NYLATRON® NSM NYLON

Nylatron® NS and Nylatron® NSM nylons are proprietary bearing materials based on well-known Nylatron® and Wear Rate, Coefficient of Friction and Limiting PV Data Monocast® nylon technology. These nylon formulations Comparative contain solid lubricant additives which impart self­ Wear Rate to lubricating, high Pressure Velocity (PV), and superior wear Wear Factor Nylatron® Coefficient of Friction Limiting resistance characteristics. In many applications superior Nylon "K" (1) NSM Static (2) Dynamic (3) PV (4) wear resistance is delivered without either start-up or Nylatron® NSM 11 1.0 .12-.22 .13-.16 15,000 running lubrication. Nylatron® NS 31 2.8 .13-.18 .17-.18 11,000 Nylatron® NS Nylon Nylon 6/6 72 6.5 .17-.18 .17-.43 2,700 This material is a type 6/6 extruded nylon compound with Nylatron® GSM 88 8 .17-.23 .16-.17 3,000 special additives offering superior bearing properties. It is Nyloil (a) 100 9.1 .17-.20 .11-.13 4,150 recommended for applications where, in addition to superior bearing performance, other traditional 6/6 nylon properties MC®901 130 11.8 .17-.23 .16-.17 3,000 also are desired. (1) Measured on 1/2" I.D. journal bearings at 5000 PV (1181pm & 42.2 psi) Nylatron® NSM Nylon K = h/PVT x 10·" This formulation is based on a Monocast® process using (cu.in.min./ft.lb.hr.) where h = radial wear (in) type 6 nylon and was developed for demanding applications P = normal pressure, (psi) where larger-size parts are required. The Monocast® V = sliding speed, (fm) process permits the production of massive shapes not T = test duration, (hrs) possible with standard extrusion. (2) Measured on thrust washer bearing under a normal load of 50 lbs. Gradually increasing torque was applied until the bearing completed at Lower Cost In Use 90° rotation in about one second. The "k" factor is a measure of the wear rate for materials. (3) Measured on thrust washer testing machine, unlubricated @ 20 fpm A low "k" factor indicates a low wear rate (better wear & 250 psi. resistance). The chart above provides wear and coefficient (4) Limiting PV (Test value-unlubricated@ 100 fpm (lb. ft/in.' min.) of friction data, and limiting PV values for various bearing (a) Cast Nylon Ltd. materials including standard Nylatron® GSM nylon. This data was generated using standard bearing test procedures. Key Benefits Nylatron® NSM The data, for example, show that Nylatron® NSM wears 5.9 • Little or no lubrication Nylon times longer than Nyloil. Note that our standard Nylatron® • Higher PV's Rod GSM nylon has better wear resistance than most "premium • Low coefficient of friction Diameter: 2" to 28" price" bearing materials. Applications can now be upgraded • Non-squeaking Length: To 5½" diameter - from standard materials to Nylatron® NS and Nylatron® NSM • Low wear rate 2 ft. nominal nylon at a lower total cost. • Excellent cost/ 4 ft. lengths also available Typical Applications performance ratio Over 5½" diameter - • Corrosion resistant 1 ft. nominal • Bushings • Valve seats • Guides • Non-abrasive • Wear plates • Thrust bearings • Cams • Slide bearings • Seals • Wear strips Plate • Rubber blocks Availabilities Thickness: 3/16" to 4": Nylatron® NS Nylon Plate Size: 24" x 48" Rod standard 48" x 48" available as cast Diameter:¼" to 2"

Length: 8 ft. nominal Tubular Bar O.D.: 2" to 38" Plate I.D.: 1 " to 35" Thickness: ¼2" to 2" Standard length: 26" Plate Size: 24" x 48" Gear Ring Blanks Other sizes of rod and plate O.D.: 2" to 80" plus strip, profile and tubular 1" to 3" bar available upon request. Standard length: 26"

Gear Ring Blanks O.D.: 2" to 80" 1.D.: 1" to 73" Length: 1O" maximum

Gear Blanks Diameter: 2" to 48"

63

Test z Method MC®901 and Nylatron® Nylatron® Prooertv Units ASTM Nvlatron® GS Nvlatron® GSM NS Nvlon NSM Nvlon 101 Mechanical Specific Gravity - D-792 1.14-1.18 1.15-1.17 1.18 1.15 1.14-1.15 -< Tensile Strength, 73°F psi D-638 10,000 - 14,000 11,000 - 14,000 10,500 10,000 - 12,000 9,000-12,000 r- Tensile Modulus of Elasticity, 73°F psi D-638 450,000 - 600,000 350,000 - 450,000 408,000 450,000 250,000 - 400,000 0 Elongation, 73° F % D-638 5 - 150 10- 60 10 50- 70 20-200 Flexural Strength, 73°F psi D-790 16,000 - 19,000 z 16,000 -17,500 14,500 16,000 12,500 - 14,000 Flexural Modulus of Elasticity, 73° F psi D-790 400,000 - 500,000 - 400,000 400,000 175,000-410,000 a Shear Strength, 73°F psi D-732 9,500 - 10,500 10,500 - 11,500 9,000 10,000 9,600 Compressive Strength psi D-695 12,000 - 13,000 - 12,500 - 12,000 0 Compressive Modulus of Elasticity, 73° F psi D-695 - - - - - Coefficient of Friction (Dry vs. Steel) Dynamic - - .15- .35 .15 - .35 .17 - .38 .13 - .16 .17 - .43 Hardness, Rockwell, 73°F - D-785 R110-125 R112 -120 116 115 R110 - 120 D-676 D80 - 90 Durometer, 73° F - - 86 86 D80 - 85 ft.lb.Jin.' D-1822 50 - 180 80 - 130 Tensile Impact, 73° F 122 70 90 - 180

Thermal

Coefficient of Linear :XJ 5 5 5 5 5 Thermal Expansion in./in./°F D-696 3.5 X 1 0· 5.0 X 1 0· 5.5 X 10· 5.0 X 1 0· 5.5 X 10·

Deformation under Load (122° F 2,000 psi) D-621 0.5 - 2.5 0) % 0.5 - 1.0 .65 .90 1.0 - 3.0 .i,. Deflection Temp. 264 psi OF D-648 200 - 470 200 - 425 200 200 200- 450 66 psi OF D-648 400- 490 400 - 425 - - 400 - 460 - Melting Point OF D-789 482 - 500 430±10 482 - 500 446 - 493 482 - 500 Continuous Service Temp. < in Air /Maximum\ OF - 180 - 200 200 - 225 220 180-200 180-200 rn Electrical Dielectric Strength 7J Short Time volts/mil D-149 300 - 400 500 - 600 - - 300- 4002 13 Volume Resistivity ohm/cm D-257 2.5 X 1 0 - - - 4.5 X 1 013 Dielectric Constant 60 Hz D-150 - 3.7 - - 4.1 :XJ 103 Hz D-150 - 3.7 - - 4 106 Hz D-150 - 3.7 - - 3.4 0 Chemical Water Absorption Immersion 7J 24 Hours % D-570 0.5 - 1.4 0.6 - 1.2 1.0 1.2 0.6 - 1.5 Saturation % D-570 6-8 5.5 - 6.5 7.5 5.3 7-9 rn Acids, Weak, 73°F A A u A A Strong, 73° F u u A A u Alkalies, Weak, 73° F A A A A A Strong, 73° F A A A A A - Hydrocarbons, Aromatic, 73° F A A A A A rn Hydrocarbons, Aliphatic, 73° F A A - - A Ketones, 73° F A A - - A C/) Ethers, 73° F A A - - A Esters, 73° F A A - - A Alcohols, 73° F A A - - A Inorganic Salt Solutions, 73° F A A - - A Continuous Sunlight, 73° F L L - - L

NYLON 101

Nylon 101 ASTM Nylon 101, a type 6/6 nylon, was the Property Units Method 101 (6/6) first nylon material available in rod, Mechanical sheet and tube form for industrial use Specific Gravity - D-792 1.13- 1.15 and, since its introduction in 1946, Tensile Strength -40°F psi D-638 15,700 psi D-638 12,000 has become the most widely used 73°F 170° F psi D-638 9,000 nylon in American industry. Its broad Elongation -40°F % D-638 20 acceptance in such diverse industries 73°F % D-638 60 as food processing (FDA approved), 170° F % D-638 340 machinery and electronics has come Modulus of Elasticity 73°F psi D-638 410,000 about because of the premium prop­ Flexural Strength 73°F psi D-790 12,500 - 14,000 erties it offers. Nylon 101 is the strong­ Impact Strength, lzod -40°F ft.lb.fin. D-256 0.60 est, stiffest, and has the highest melt­ 73°F ft.lb.fin. D-256 1.0 ing point of any unmodified nylon Shear Strength 73° F psi D-732 9,600 psi D-695 4,900 processed by conventional extrusion Compressive stress at 1% deformation 73° F Stiffness 73°F psi D-747 250,000 - 400,000 techniques, and replaces a wide range Hardness, Rockwell 73°F D-785 R118,M79 of conventional materials-including Tensile Impact, long specimen 73°F ft.lb.fin.' D-1822 240 steel, bronze, brass, aluminum, lami­ short specimen 73°F ft.lb.fin.' D-1822 75 nated phenolics, wood and rubber. It Thermal can replace such vastly different ma­ Coefficient of Linear Thermal Expansion in.fin.I° F D-696 4.5 X 10-5 terials as steel and rubber because its Deformation under Load (122° F 2000 psi) % D-621 1.4 properties - low friction, high Deflection Temperature° F 264 psi OF D-648 220 strength, toughness and good abra­ 66 psi OF D-648 470 sion resistance-lie between those of Thermal Conductivity BTU/hr./ rubber and steel. It is this combina­ sq.ft./° Flin. 1.7 tion of properties, rather than a single Flammability in./min. D-635 self- area of superiority, which make nylon extinguishing Melting Point (Fisher-Johns) OF D-789 482 - 500 101 so useful for many different appli­ OF D-2117 518 cations.

Rd0 Lengths & ToI erances Sheet Sizes & Tolerances Lengths Tolerances Tolerance Slab Size 1/16" to 3/16"-8 ft. 1/16" to 1" +.002"-.000" Thickness Length & Width

1/4" to 1"-5 & 10 ft. 1¼" to 2" +.005"-.000" 12" X 48" 1/16" to 3/16" ±.01o -.000 +.125 1¼" to 2"-4 & 8 ft. 2¼" to 3" +.025"-.000" 24" X 48" 1/4" to 7/8" +.025 -.000 2¼" to 3"-2 & 4 ft. 3¼" to 4¾" +.187"-.000" over 1" +.050-.000 3¼" & over-1 & 2 ft.

Typical Applications • Bearings • Rollers • Fasteners • Bushings • Guides • Sleeves • Valve seats • Gears • Liners • Thrust washers • Insulators • Tooling Fixtures • Seals • Cams and cam followers • Forming dies • Wear surfaces

Properties • High wear and abrasion resistance • Low coefficient of friction • Resilience and impact resistance • Non-abrasive to other materials • Noise dampening characteristics • Good electrical insulating properties • Resistance to alkalies and organic chemicals • Able to operate with or without lubrication • FDA approved • Light weight • Conformability

65

NYLON ZVTEL ® ST 801

Zytel® ST 801 HS super tough nylon resin Availability is a heat stabilized member of the new fam­ ily of tough nylon resins, Zytel®ST 801 HS Rod Slab provides resistance to embrittlement at ele­ 1/4" to 2" dia. 1" to 2" thickness vated service temperatures while maintain­ Standard lengths: Standard sizes: ing an extremely high impact strength and 8 ft. to 1o ft. 12"x48", 24"x48" the notch insensitivity associated with Zytel® ST 801. Zytel® ST 801 HS retains its tough­ Benefits ness even under adverse conditions such as low moisture content and low tempera­ Zytel® ST 801 HS offers a new combination tures.Zytel®also maintains outstanding res­ of benefits to processors and end users. istance to both crack initiation and crack propagation. Features Benefits The combination of strength, chemical, • Outstanding Increased and heat resistance, and lack of notch sen­ toughness Design flexibility sitivity makes Zytel®ST 801 HS the material Product reliability of choice in many demanding applications. Abuse resistance These applications include components, • Chemical and heat Useful in hostile power tool housings, outdoor power equip­ resistance environments ment, machinery parts and electrical hard­ • Easy fill/fast-mold- Higher productivity ware.Zytel®ST 801HS can be considered as ing cycles Lower costs a replacement for both metals and polycar­ bonates in applications not requiring trans­ • Good surface and Excellent parency. colorability appearance

PROPERTIES TEST UNITS VALUE Tensile Strength ASTM D-638 psi Dry, 23° C (73° F) 7,500 50% R.H., 23° C (73° F) 6,000 Elongation ASTM D-638 % Dry, 23° C (73° F) 60 50% R.H., 23° C (73° F) 210 Flexural Modulus ASTM D-790 K psi Dry, 23° C (73° F) 245 50% RH, 23° C (73° F) 125 Rockwell Hardness ASTM D-785 R Scale Dry, 23° C (73° F) 112 lzod Impact Strength ASTM D-256 ft. lb.fin. Dry, 23°C (73° F) (10 mil notch radius) 17.0 50% R.H., 23° C (73° F) >20.0(3) Dry, 23° C (73° F) Special Test 17.0 (2 mil notch radius) Heat Deflection Temperature (annealed) ASTM D-648 0.5 MPa ( 66 psi) oc 216 1.8 MPa (264 psi) 71 Melting Point ASTM D-789 oc 255 Specific Gravity ASTM D-792 1.08 Mold Shrinkage in.fin. .013-.018 Combustibility UL-94 94 HB Water Absorption-100% R.H. % 6.7

66

POLYCARBONATE - MACHINING GRADES

Polycarbonate is a transparent thermoplastic which offers very high impact strength and high modulus of elasticity as a machined part. The material has a high heat distortion POLYCARBONATE temperature and absorbs almost no moisture. These properties, in addition to good electrical characteristics, STIFFNESS VS. TEMPERATURE make polycarbonate a prime material for electrical/electronic applications. Its strength, impact resistance and transparency also make it an ideal material ....-ACETAL for certain transparent structural applications.

Polycarbonate mill shapes are produced from ;;; polycarbonate resins which meets the requirements of :; c::, 300 t----'"t----r:::.....:::-- ;:::0.... ---'"""-:::+ -----1 Federal Specification LP-393a. c::,

Cl) Polycarbonate is readily machined on standard 200 i-----....,..,r----i-...----"t ----- ­ metalworking equipment. It can be drilled, sawed, turned, Q shaped, milled, punched, filed, sanded and buffed. 0 == KEY PROPERTIES: 100 t----+----':::..... ---==---:-:! ------1

• High impact strength 0 . ...__ _.__ . , .., _ _.__ _,__ , • Excellent strength retention at elevated temperatures 50 100 150 200 250 300 350 TEMPERATURE, °F • High tensile, shear and flexural strength • High modulus of elasticity, low deformation under load • Excellent resistance to creep and cold flow • Low coefficient of thermal expansion • Good electrical insulation properties TYPICAL APPLICATIONS: • Coil forms MINIMAL DIMENSIONAL CHANGE • Insulators • Connectors DUE TO MOISTURE 11 • Rollers DIMENSIONAL CHANGE DUE TO MOISTURE: 1.0 E UILIBRIUM IN WATER @72°f• • Impellers • Fittings 0.9 • Handles 0.8 • Instrument windows 0.7 NYLON • Covers (50%R.H.) u.i 0.6 PROPERTIES: en < • High impact strength IJJ 0.5 au: • Excellent strength retention at elevated temperatures :!: 0.4 a: • High tensile, shear and flexural strength < 0.3 zIJJ • High modulus of elasticity, low deformation under load :::; • Excellent resistance to creep and cold flow 0.2 POLYCARBONATE • Low coefficient of thermal expansion 0.1 POLYSULFONE • Good electrical insulation properties 0 0.5 1.0 1.5 2.0 2.5 3.0 AVAILABILITIES MOISTURE ABSORBED, % *Note: Polycarbonate is not recommended for ROD: use where water tern eratures exceed 180°F Diameter: 1/32" to 6" . Length: To 2 %" diameter-8 ft nominal Over 2 %" diameter-4 ft. nominal PLATE: Thickness: 1 / 32" TO 3" Size: 24" x 48" SPECIAL ORDERS: Other sizes and shapes including tubing, strip, disc, tubular bar and profile extrusions are available.

67

PROPERTIES OF POLYCARBONATE & GLASS-FILLED POLYCARBONATE

Test 10% 20% 40% Method Polypenco® Glass Filled Glass Filled Glass Filled Proaertv Units ASTM Polvcarbonate Palvcarbonate Polvcarbonate Polvcarbonate Mechanical Specific Gravity - D792 1.2 1.25 1.35 1.52 Tensile Strenath, 73°F psi D638 9,000-10,500 8,000 16,000 23,000 Tensile Modulus of Elasticity, 73°F psi D638 320,000 - - - Elonaation, 73°F % D638 60-100 - 4.6 3.5 Flexural Strenath, 73°F psi D790 11,000-13,000 15,000 19,000 27,000 Flexural Modulus of Elasticity, 73°F PSi D790 375,000 Shear StrenQth, 73°F psi D732 9,200 Compressive Strenath, 10% Del. osi D695 11,000 Compressive Modulus of Elasticity, 73°F psi D695 240,000 Coefficient of Friction /Drv vs. Steel) Dvnamic - - - Hardness, Rockwell, 73°F - D785 R118 Durometer, 73° F - D676 70 85 91 93 Tensile Impact It. lb.fin. D1822 225-300

Thermal Coefficient of Linear Thermal Exoansion in./in./°F D696 3.9x10' Deformation Under Load (122°F, 2,000 psi) % D621 0.36 Deflection Temperature 264 psi OF D648 280-290 288 295 295 66 osi OF D648 283-293 295 300 310 Meltina Point OF D789 - Continuous Service Temperature in Air (Max.) OF - 250 Electrical Dielectric Strenath Short Time Volts/mil D149 >400 450 490 450 Volume Resistivitv OHM-CM D257 2.1 X 10" Dielectric Constant, 60 Hz - D150 3.17 3.10 3.0-3.53 3.53 10'Hz - D150 - 3.05 - - 10'Hz - D150 2.96 Dissioation Factor, 60Hz - .0009 .0075 .0009 - 10Hz - - Chemical Water Absorption Immersion 24 Hours % D5705 0.2 .12 .12 .12 Saturation % D570 - Acids, Weak, 73°F A A A A Strano, 73°F A A A A Alkalies, Weak, 73°F u u u u Strona, 73°F u u u u Hvdrocarbons-Aromatic, 73°F u u u u Hvdrocarbons-Aliphatic, 73°F A A A A Ketones, 73°F u u u u Ethers, 73°F A A A A Esters, 73°F u u u u Alcohols, 73°F A A A A lnoraanic Salt Solutions, 73°F A A A A Continuous Sunliaht, 73°F - - - -

Glass fiber reinforcement in engineering plastics yields higher defection temperatures. They exhibit enhanced products with superior physical characteristics and resistance to sustained high temperatures and better exceptional strength-to-wear ratios. These products are dimensional stability, producing a plastic product that can offered in custom extruded rod form and plate. frequently replace metals. Due to their superior characteristics, glass-reinforced plastics are also versatile Glass reinforced plastics offer greater tensile strength, from an original design standpoint. higher impact strength, greater stiffness and higher fatigue endurance limits than non-glass reinforced materials. Various glass reinforcement levels are available. The most common include 10 percent, 20 percent and 30 percent In addition, glass-reinforced thermoplastics retain their glass. tensile strength at high temperatures and have significantly

68

POLYCARBONATE - LEXAN® GP SHEET

DESCRIPTION TYPICAL PROPERTIES VALUES LEXAN® 9034 uncoated polycarbonate Test sheet is the standard grade of LEXAN sheet Method Units Value for transparent protective glazing. High­ impact LEXAN 9034 sheet can be utilized for PHYSICAL primary glazing, or on either side of existing Specific Gravity ASTM D792 - 1.20 glazing for economical protection against Refractive Index@ 77'F ASTM D542A - 1.586 breakage or intrusion. A better insulator than Light Transmission (Average), 1/8' disk ASTM D1003 % 88 glass, LEXAN 9034 sheet contributes to Rockwell Hardness ASTM D785 - M70 lower energy costs. Abrasion Resistance, Taber Abrader, CS-17 wheel ASTM D1044 mg/1,000 cycles 10 PRODUCT FEATURES Water Absorption, Equilibrium, 24 hrs. ASTM D570 % 0.15 @73'F 0.35 • UV Stabilized @212'F 0.58 • Clear, polished surface

• Privacy & prismatic patterns available MECHANICAL Tensile Strength ASTM D638 psi THERMAL PROPERTIES @Yield 9,000 Polycarbonate insulates effectively, Ultimate 9,500 particulary vs. glass. It is often used as over­ Tensile Modulus ASTM D638 psi 345,000 glazing on old existing sash windows for Flexural Strength ASTM D790 psi 13,500 significant energy savings, protection Flexural Modulus ASTM D790 psi 345,000 against vandalism, and to improve the Flexural Endurance ASTM D671 psi appearance of a building. @1,800 cycles/min, 73'F, 50% RH 1,000 CONSTRUCTION AND AGENCY CODE Compressive Strength ASTM D695 psi 12,500 RATINGS Compressive Modulus ASTM D695 psi 345,000 Elongation ASTM D638 % 110 General Purpose polycarbonate sheet satisfies major building code requirements Poisson's Ratio - - 0.37 for glazing and construction applications. lzod Impact Strength ASTM D256A It-lbs/in This performance is backed by extensive Notched@¼" 12-16 application history. In addition, standard and Unnotched @¼' 60 (no failure) flame inhibiting grades carry Underwriters' Tensile Impact Strength, s-Type Specimen ASTM 1822 It-lb/in' 225-300 Laboratories 94 V-2 and V-0 ratings­ Shear Strength ASTM D732 psi depending on grade and thickness. @Yield 6,000

LIGHT TRANSMISSION AND Ultimate 10,000 WEATHERING Shear Modulus ASTM D732 psi 114,000 Deformation Under Load @4,000 psi ASTM D621 % General Purpose polycarbonate sheet @73'F 0.2 transmits light, based on thickness from 82- @158' 0.3 89%. Like all standard polycarbonate and other plastic glazing products, outdoor THERMAL exposure will effect surface coloration and Coefficient of Thermal Expansion ASTM D696 in/in(F 3.75 X 10·5 gloss to various degrees depending upon Coefficient of Thermal Conductivity ASTM C177 Btu/hr/lt'(F/in 0.2255 X 10' the duration and intensity of exposure. Specific Heat@40'C cal/gm(C 0.30 These visible weathering effects can be Heat Deflection Temperature ASTM D648 'F minimized over time with periodic cleaning @264 psi 270 according to recommendations. Also, solar @66 psi bronze or gray tints reduce the visible 280 effects of UV exposure. Even after extended Brittle Temperature ASTM D746 'F -211 weathering, the toughness of polycarbonate ELECTRICAL sheet far surpasses non-weathered acrylic. Dielectric Constant ASTM D150 - @10Hz 2.96 @60Hz 3.17

Volume Resistivity ASTM D257 ohm-cm 8.2 X 10" Power Factor ASTM D150 @60Hz 0.0009 @1,000,000 Hz 0.010 Arc Resistance ASTM D495 sec Stainless Steel Strip Electrodes 10-11 Tungsten Electrodes 120

FLAMMABILITY

Horizontal Burn (Flame Spread) ASTM D635 AEB in <1

69

POLYCARBONATE-LEXAN® SPECIALTY GRADES

F-2100 Lexan Sheet Applications-Series 9600 Sheet was created to provide the improved flammability required to meet appropriate Lexan® Sheet F-2100 is a transparent, polycarbonate sheet industry codes for power tools, electrical appliances, designed to anticipate the implementation of new, more communication equipment, business machines, safety stringent combustion standards in glazing applications. This equipment and aircraft components. grade differs from standard Lexan® sheet in that the benefits of a new Lexan® technology are used to provide the best F 6000 Aircraft Grade-Flame Retardant balance of combustion characteristics, including flammability, smoke and toxicity, while maintaining the high Premier Chemical and Flame Resistant for Tough, impact properties of standard Lexan® Sheet. F-2100 is Lightweight Aircraft Interior Components. The Lexan® F available in clear and solar tints. 6000 Sheet series is a family of new opaque polycarbonate sheet products designed to meet increasingly stringent Lexan® Sheet F-2100 offers these advantages: requirements for aircraft interiors. Polyvinyl fluoride (PVF) film overlays laminated to Lexan® sheet provide improved • Combustion characteristics: chemical and stain resistance, along with excellent Excellent smoke characteristics-easily meets smoke flammability properties including low flame spread, low emission requirements as proposed by various smoke and low toxicity. governmental agencies-NBS Smoke Chamber maximum These features, along with high impact strength, Ds of 200 at 4 minutes. exceptional dimensional stability, extreme temperature Meets the requirements of FAR 25.853, Area I, in gauges of performance and rigidity, make Lexan® F6000 sheet 125 mils and above. Anticipates the need for reduced products ideal for a variety of aircraft interior components. toxicity of combustion products (tests conducted by an And because they are thermoformable, designers can independent laboratory indicate a level approximately that explore new options for construction and appearance. of red oak wood.) The Lexan® F6000 Sheet family is available in a variety of F-2100 Lexan® Sheet has been tested in large-scale, colors and gauges. It includes Lexan® F6000 Sheet with 2 documented, window and wall panel combustion trials mil opaque PVF film overlay; Lexan® F6040 Sheet with 4 mil (results are available for discussion). opaque PVF film overlay; and Lexan® F 6050 Sheet with 1.5 mil. clear PVF film overlay. • Excellent weathering resistance and U.V. stability as indicated by RS sunlamp and Atlas Weatherometer Easily Thermoformed for Crisp, Complex Detail. The exposure testing. outstanding heat resistance and broad plastic range of Lexan® F6000 Sheet products make them ideal for • The high impact strength inherent in polycarbonates is thermoforming tough, detailed parts of all sizes. Window retained. reveals, ceiling panels, stow bins, seat trim and wainscoting can be readily manufactured using common thermoforming • Energy saving, insulating properties superior to standard techniques and equipment. Formed parts can be machined plate glass. by conventional sawing, shearing, drilling or routing • Excellent formability-may be formed into curved or angle equipment. Formed parts can be machined by conventional shapes for architectural designs of balustrades, skylights sawing, shearing, drilling or routing equipment. They may be and domes. joined to themselves by adhesives, heat sealed, mechanically fastened or bonded to other materials. While resistance to mold cleaning agents and environmental chemicals is generally good, Lexan® Sheet MR5 Abrasion Resistant Sheet F-2100 is subject to attack by certain types of chemicals. MR5 is a specially coated sheet that is resistant to Suggested Applications-F-2100 is particularly suitable scratching and abrasion. MR5 lets you maintain a clean clear for architectural glazing applications where improved surface despite frequent cleanings. Its abrasion resistance combustion characteristics are desired over standard approaches glass and is the most resistant clear plastic polycarbonate sheet. material available. 9600 Lexan® Polycarbonate-Flame Retardant Sizes:.125" to.500" thick Lexan® Sheet Series 9600 offers significantly better LT300 Lexan Polycarbonate Sheet flammability characteristics than conventional Lexan® polycarbonate sheet. It is formulated to meet the standards LEXAN LT 300 sheet is a general purpose, modified of UL Bulletin, Class I. (Certain colors are limited to Class II polycarbonate product that offers excellent low temperature use.) impact strength and outstanding heat resistance. Suitable for applications requiring durability and toughness, LEXAN The improved flammability and slightly higher heat LT 300 sheet offers superior performance at a competitive deflection temperatures (5 to 1 0 degrees) of Series 9600 price. Sheet are accompanied by essentially the same physical, electrical and chemical properties exhibited by the Color: Grey and Black conventional Lexan® sheet. Series 9600 Sheet is a 100% Gauge: .030-.250 polycarbonate composition and does not include any of the additives used in plastics to achieve non-flammability. Weight::.58-.78 pounds per square foot Fabricating properties are identical to those associated Tolerances: Width +1"-0, length +1" with general purpose Lexan® sheet. Sheet Sizes: 4', 5', 6' and 8' Textures: Haircell, Matte

70

POLYCARBONATE-LEXAN® SHEET PROPERTIES

Test Method Lexan Lexan Lexan Lexan Lexan Prooertv Units ASTM LT-300 MRS F2100 9600 F6000 Specific Gravity - D-792 1.20 1.20 1.22 1.23 1.21 Tensile Strenath, 73°F psi D-638 9,000 9,500 9,500 9,500 9,000 Tensile Modulus of Elasticity, 73°F psi D-638 340,000 345,000 345,000 340,000 325,000 Elonaation, 73°F % D-638 - 110 110 110 95 Flexural Strength, 73°F psi D-790 13,500 13,500 13,500 13,500 13,200 Flexural Modulus of Elasticitv, 73°F psi D-790 340,000 345,000 340,000 340,000 325,000 Shear Strenath, 73°F PSi D-732 - 10,000 10,000 10,000 - Compressive Strenath psi D-695 12,500 12,500 12,500 12,500 12,500 Compressive Modulus of Elasticity, 73°F psi D-695 340,000 345,000 345,000 340,000 325,000 Coefficient of Friction (Dry vs. Steel) Dynamic - - - - - Hardness, Rockwell, 63°F D-785 R-118 R-118 M-72 M-70 M-70R-118 Durometer, 73°F - D-676 - - - - - Tensile Impact, 73°F ft.lb./in.2 D-1822 - - 275 Coefficient of Linear Thermal Expansion in./in./°F D-696 3.7 X 10·5 3.75 X 10·5 - 3.75 X 10·5 3.75 X 10·5 Deformation Under Load (122°F, 2,000 psi) % D-621 - - .25 - - Deflection Temperature 264 psi OF D-648 275 270 - 285 270 66 PSi OF D-648 - 280 - - 280 Melting Point OF D-789 - - - - - Continuous Service Temperature in Air (Maximum) OF ------Dielectric Strenath, Short Time volts/mil. D-149 3,900 380 380 380 Volume Resistivity ohm-cm D-257 - 8.2 X 106 >1016 2.1 X 10 16 >1016 Dielectric Constant, 60 Hz - D-150 - 2.94 2.96 2.9 3.17 10' Hz - D-150 - 2.94 - 2.9 - 106 Hz - D-150 - 2.92 2.92 - 2.96 Water Absorntion lmmersion-24 hrs % D-570 .35 - 0.15 0.15 0.15 Saturation % D-570 .035 0.33 0.32 - Acids, Weak, 73°F ------Strong, 73°F ------Alkalies, Weak, 73°F ------Strano, 73°F ------Hydrocarbons, Aromatic, 73°F ------Hvdrocarbons, Aliphatic, 73°F ------Ketones, 73°F ------Ethers, 73°F ------Esters, 73°F ------Alcohols, 73°F ------lnoraanic Salt Solutions, 73°F ------Continuous Sunlight, 73°F ------

U.L. 94 Flame Classifications A product that has a classification at a particular thickness carries that same classification in thicker gauges unless the Product Nominal Thickness product is re-tested at a thicker gauge. Thinner gauges need .010 .030 .060 .090 .1-25 .187 .250 to be tested or else the product has no formal classification at thinner gauges. 9030 V-2 V-2 V-2 V-2 V-2 V-2 For example, a product such as 9600 has a V-2 rating at 8030 V-2 V-2 nominal 30 mils. This classification covers all thicker gauges

up to nominal 90 mils. At 90 mils and thicker, the material MR5/Margard - HB V-1 V-1 has a V-0 rating. Gauges thinner than 30 mils have no formal 9600 V-2 V-2 V-0 V-0 UL rating. F2100 V-0 V-0 V-0 Classifications are also color specific. If a particular color is not listed, assume that the product in that particular color V-0 F6000 V-0 V-0 V-0 V-0 has no formal UL rating. 9440F V-2 V-2 V-2 V-2 V-2

9900 HB HB HB HB HB

71

POLYETHYLENE UHMW

UHMW is an ultra-high molecular weight, Properties of UHMWPE high-density polyethylene resin having a molecular weight range between 2 and 5 Test Method million. UHMW has one of the highest Property Units ASTM UHMWPE impact strengths of any thermoplastic, this MECHANICAL Specific Gravity - D792 0.94 material has excellent abrasion resistance, Tensile Strength, 73°F. psi D638 4,000-5,500 Tensile Modulus of 80,000- tensile strength, energy absorption, resist­ Elasticity, 73° F. psi D638 100,000 ance to stress cracking and a low coeffi­ Elongation, 73° F. % D638 200-450 Flexural Modulus of cient of friction. These properties coupled Elasticity, 73°F. psi D790 75,000 Shear Strength, 73°F. psi D732 3,500 with extremely low moisture absorption Coefficient of Friction (Dry vs. Steel) Dynamic - - .09-.12 make UHMW an exceptional material for Hardness, industrial impact, wear, and sliding appli­ Rockwell, 73° F. - D785 R64 Durometer (D/15) - D2240 67 cations. lzod Impact ft. lbs./ D256A 23°c in. notch No Break -40°C No Break Performance Properties THERMAL Coefficient of Linear Impact Resistance- UHMW has an outstand­ Thermal Expansion in./in./°F D696 7.2 X 10-5 ing ability to absorb energy. It can with­ Deformation Under Load (122°F. 2,000 psi) % D621 6-8 (6 hrs.) stand impact at temperatures as low as Deflection Temperature 264 psi OF D648 117 -140° F. 66 psi OF D648 158-174 Melting Point Of D789 266 Low Coefficient of Friction - Excellent for Continuous Service Temp. In Air (Maximum) Of - 180 use in a wide variety of sliding or rubbing ELECTRICAL applications because of its high slip charac­ Dielectric Strength Short Time Volts/mil D149 450-500· teristics and good release properties. Volume Resistivity OHM-CM D257 10" Dielectric Constant, 60Hz D150 2.3 Corrosion and Chemical Resistance - CHEMICAL Water Absorption Immersion UHMW is highly resistant to corrosion and 24 hours % D570.. .01 chemicals (see chemical resistance chart Acids, Weak, 73°F. A Strong, 73°F. L pg. 127). Alkalies, Weak, 73°F. A Strong, 73°F. A Low Moisture Absorption - UHMW absorbs Hydrocarbons- Aromatic, 73°F. L virtually no water, enabling it to be used in Aliphatic, 73°F. A Ketones, 73°F. A high moisture environments without effect­ Ethers, 73°F. A ing dimensions or properties. Esters, 73° F. A Alcohols, 73°F. A Non-toxic, Odorless, Tasteless - Because it Inorganic Salt Solutions, 73°F. A is physiologically inert and produces no Continuous Sunlight, 73° F. u harmful dermatological effects, UHMW has F.D.A. sanction for use in food handling equipment. Availability Rod Diameter:½",%",¾",¾", 1", 1¼", 1½", 1¾", 2", 2½", 3", 3½", 4", 5" Length: 5 or 10 ft. standard - longer lengths available. Plate Thickness:¼",¾",½",¾", 1", 1¼", 1½", 1¾", 2" Nominal Sizes: 24" x 24", 24" x 48", 48" x 96", 48" X 120"

72

POLYETHYLENE UHMW

Typical Applications Comparative lzod Impact Test Gears Conveyor parts D256 Bearings Wear surfaces TEST RESULT Bushings Impact surfaces MATERIAL FT-LB/IN NOTCH Sprockets Liners NO UHMW BREAKS Cams Feed screws POLYCARBONATE 12 - 16 Guide rails Starwheels POLYSTYRENE 0.5 - 12 In addition to these typical applications, RIGID PVC 0.4 - 12 UHMWPE's unique combination of properties HOPE 1.5 - 12 NYLON, GLASS FILLED 2.6 - 6.0 makes it suitable for many specific applications POLYPROPYLENE 0.6 - 6.0 such as those described below. MOPE 0.5 - 5.5 Mining - Hopper linings, chute linings, impact TFE 3.0 plates, non-stick surfaces, conveyor plates, bump­ NYLON 6 1.0- 3.6 ACETAL 1.4- 2.3 er linings, rope guides and pulleys. NYLON 6/6 1.0 Pulp and Paper-Suction box linings and covers, ACRYLIC 0.3 - 0.5 doctor blades, forming boards, water scrapers, drag chain wear strips, splitting wedges and pulp Sand Slurry Test Each material listed below was rotated 7½ hours@ 1750 r.p.m. paddles. Carbon Steel= abrasive rating of 100 Chemical - Mixer paddles and linings, hopper The weight loss for each material is relative to 100 The lower the figure, the better the abrasive resistance. linings, grinder feed chutes, digester covers, flexi­ UHMW POLYMER . . .. . 17 TFE/glass fiber ...... 113 ble mixer shafts, conveyor wear strips. Nylon ...... 31 Normal MW Materials Handling - Conveyor star wheels, High MW polyethylene ...... 125 polyethylene ...... 44 Phosphor bronze ...... 193 guides, wear plates and timing screws, chutes and TFE ...... 72 Yellow brass ...... 409 chute linings, conveyor wheels and guides, glue Stainless Steel ...... 84 Phenolic laminate ...... 571 sealer surfaces. Polypropylene ...... 87 Hickory wood ...... 967 Polycarbonate ...... 96 Hi Carbon Steel ...... 100 Food and Packaging - Cutting boards, mixer Polyacetal ...... 11O paddles, washers, guides and pulleys for food processing equipment, screw conveyors for mash I I and fruit pulp, guide and deflector rollers for bottle L - a IN SHAfl filling and labeling machines. I

Textile - Weaving loom pickers, picker caps, COUPON striker bars, picker shields, thread guides, clap­ ,... PLAIN WASHER pers, buffers and collecting rollers. -. lOCKWASHER Metalworking - Stock feed tubes for automatic HEXNI.H screw machines and turret lathes. Sports Equipment-Ski soles, skids for sailplanes, snowmobile slide rails. C> I·:: t --- Jl!I TESTCOUf'ON

Table 2 - Impact and Abrasion Test Data Tensile Impact Taber Abrasion Sand Slurry* Notched lzod Type L CS 17/1000 gr/5000 Rev. 50/50 Sand-Water ft-lb/in. notch ft-lb/ in. 2 (milligram loss) 1725 RPM, 7 hrs UHMW 32+ 1000 Nil 15 Polyurethane 3 Polyester 10 HOPE 1-20 50-400 29 86 PTFE 3 200 42 72 Nylon 6/6 2-5 300 49 31 Polycarbonate 16 400 50 96 LOPE 70 Acetal 1-2 110 70 110 ABS 3-10 225 275 Polystyrene 325 Polypropylene 5-4 75 304 Stainless 84 Phosphor Bronze 190 Polysulfone 300 Maple Wood 690 *Lower wear factor = better abrasion resistance

73

POLYETHYLENE-UHMW-SOLIDUR®

Phvsical Properties (a} Test Method (bl Solidur Ceram-P Solidur 10100 UHMW Polymer Solidur 10802 AST Polymer Solidur 10605D$ Polymer Solidur 25 Reclaim Polymer Density, q/cm 3 ASTM D792 0.98 .93 .97 .96 .94

lzod Impact strength at 23°c, ft-lbs/in. Double-notched ASTM D256A 17-23 32 30 28-30 18

Hardness, Durometer (D15)

Hardness, Rockwell "R" ASTM D 785 Not Available 65 65 68 68 Hardness, Shore "D" ASTM 2240 67-68 Abrasion Test Internal% 80-85 100 90 85 90

Tensile Properties@ yield (psi) ASTM D 638 2600-2900 3330 3200 3200 3400 2 in/min

Elongation @ break (psi) ASTM D 638 4200-5300 6000 5600 6100 4900 @break(%) ASTM D 638 >300 450 370 333 321

Coefficient of friction Dynamic w/water ASTM D 1894 0.1 .1-.12 .08-.10 .08-.10 .15-.18

Flexural modulus, 1% secant, osi (MPa) ASTM D 7908 155 172 172 135 152

Mean coefficient of linear thermal expansion, per 0 c 1, 4 4 4 4 o to 30°c Leitz Dialatometer 1.3 X 10· 2 X 10· 1.8 X 10· 1.8 X 10· 1.6 X 104

Compressive Deformation(%) 1ooo lbs at 50°C, 24 hrs. ASTM D 621 6-8%

Water Absorption ASTM D 5706 Nil

Electrical Properties 15 15 15 Volume Resistivity Q cm ASTM D 257 > 10·15 >10 (3) See Solt -305A >10 >10 13 13 Volume Resistivity Q cm ASTM D 257 >10·12 >10 (3) >1013 >10

Dielectric Strength KV/cm ASTM D 149 900 900 50 900 900

Ceram -P Virgin UHMW-PE, i>V> 28-30, 5-6 million molecular weight, Inorganic fillers improve wear resistance, manufactured in accordance with U.S. Patent, not FDA/USDA accepted. The best wear resistant UHMW filled product available. Used in many high wear areas. 10100 Standard, natural, virgin UHMW-PE, I.V. 20-30 3.5-6 million molecular weight, FDA/USDA accepted. UV Stablized is available for outdoor applications. 10802AST Electrically conductive to reduce static electricity build-up, also a degree of UV Stabilization. Has been used extensively in conveyor industry with new electronic measuring and counting. Also used in grain and areas where static build-up is a concern. 10605D$ Virgin UHMW-PE, I.V. 28-30 5-6 million molecular weight, crosslinked, not FDA/USDA accepted, Improved wear. 25 Reclaim Reclaimed blend UHMW-PE, I.V. 20-30, part reclaimed-3.5-6 million molecular weight, part virgin-3.5-6 million molecular weight, not FDA/USDA accepted.

74

POLYETHYLENE TEREPHTHALATE (PET)

ERTALYTE® Ertalyte® is an unreinforced, partly crystalline thermoplastic Linear thermal expansion of ERTALYTE polyester based on polyethylene terephthalate (PET). It is versus some other engineering plastics characterized as having excellent wear resistance and a low 0.8 coefficient of friction, together with high modulus, low creep and superior dimensional stability. Ertalyte's specific properties make it especially suitable for the manufacture of 0.6 mechanical precision parts which are capable of sustaining 0 high loads and wear conditions. Ertalyte's continuous C: 0 'vi 0.4 service temperature is approximately 10% higher than C: acetals, and its melting point is almost 150°F higher. a. "X ' Ql In addition, Ertalyte® PET offers good strength combined "ffi 0.2 E with good chemical and abrasion resistance. Its low ai moisture absorption enables its mechanical and electrical = properties to remain virtually unaffected by ambient Ql 0.0 "C:' moisture. These qualities, combined with FDA compliance, ::::; make Ertalyte® PET an excellent candidate for certain food contact applications. -0.2

-0.4

0 50 100 150 200 Temperature 'F

Typical Applications Ertalyte• • Bearings Pronertv PET Semi-crystalline • Bushings Product Thermoplastic • Seals Oescrintion PoIvester • Spacers Mechanical Snecific Gravilv 1.39 • Thrust washers Tensile Strennth, 73"F 12.400 Tensile Modulus of Elasticitv, 73"F 423,000 • Rollers Elonoation, 73"F 20 • Guides Flexural Strennth, 73'F - • Insulators Flexural Modulus of Elasticitv, 73'F - • Food contact parts Shear Strenath, 73"F • Pump components Comnressive Strenath, 10% Def. 15,000

• Valve parts Comnressive Modulus of Elasticitv, 73'F Coefficient of Friction (Dry vs. Steel) Dynamic@ -

Hardness. Rockwell, 73'F M93-100 Availabilities Durometer, 73"F 087 Rod Tensile lmnact 50 Diameter: 1/2" to 6" Thermal Coefficient of Linear Thermal Exnansion 3.3 X 10·' Length: Deformation Under Load 1122· F, 2,000 nsil - Deflection Temoerature 264 nsi 215 To 2 3/4" diameter - Ta-Glass transition lamorohousl - 8 ft. nominal Meltina Point /crvstallinel 491 Over 2 3/4" diameter- Continuous Service Temaerature in Air /Max.\ 212 4 ft. nominal Electrical Dielectric Strennth Short Time 385 Plate Volume Resistiviru 5.5 X 10" Thickness: 1/2" to 2" Dielectric Constant, 60Hz - Size: 24" x 48" standard 10'Hz - 10'Hz -

Dissioation Factor, 60Hz - 10Hz - Key Benefits Chemical Water Absorotion Immersion 24 Hours 0.07 • High strength and rigidity Saturation 0.50 • Low moisture absorption Acids, Weak, 73'F A • Superior chemical resistance compared to nylon and actal Stronn, 73'F u • Good abrasion resistance Alkalies. Weak. 73'F A Stronn, 73'F u • FDA compliant Hvdrocarbons-Aromatic, 73"F - (Regulation #177.1630) Hvdrocarbons-Alinhatic, 73'F u • Good electrical properties Ketones. 73'F A • Excellent dimensional stability Ethers, 73' - • Weather resistance Esters. 73"F A • Radiation resistance Alcohols, 73'F A lnornanic Salt Solutions, 73'F - Continuous Sunlinht, 73'F L

75

POLYPROPYLENE Polypropylene offers a good balance of overall Chemical Resistance-It has excellent resistance to a physical properties. These properties include chem­ greater variety of chemical reagents at temperatures ical, moisture and heat resistance. Polypropylene higher than those tolerated by other thermoplastics. resists chemical attack and staining through expo­ It is unaffected by aqueous solutions of inorganic sure to aqueous solutions of inorganic salts, min­ salts and by practically all mineral acids and bases, even when highly concentrated at temperatures over eral acids, and bases. 140° F. It resists 80%sulphuric acid and concentrated Applications hydrochloric acid up to 212° F. In the presence of Polypropylene provides remarkable performance, strong oxidizing chemicals, suitable anti-oxidants compared to most thermoplastic products, in applica­ should be added to the polypropylene. It is practically tions never before possible with thermoplastics. immune to stress cracking when exposed to alcohols, soap solutions, synthetic detergents, acetic acid. Applications include: Gas Barrier-It has excellent resistance to gas and • Chemical ... tanks, scrubbers and ducts water vapor. • Electronic ... radio and TV equipment Formability and Fabrication-The same techniques • Electrical ... home appliances used in forming and fabricating linear polyethylene • Automotive ... battery cases, under-hood covers are used here. and shrouds, and non-structural uses such as Machinability-Easily machined at relatively high fender extenders speeds, on conventional machine tools. Polypropy­ • Electroplating ... plating barrels lene can also be fabricated on standard woodworking • Photo and film industry ... sinks and developing equipment such as molders, dowelers and planers. trays Bonding-Because of its outstanding resistance to • A replacement for wood in furniture and musical chemicals, polypropylene does not lend itself to sol­ instrument construction vent bonding or cementing. However, joints of great • FDA Approved strength can be obtained by hot nitrogen welding, Availability spin welding, and hot plate fusion. Rod from 1/8" to 14" diameter Sheet and slab from .030" to 6" thick ASTM Property Unit Test No. P.P. Standard Lengths: Mechanical 1/4" to 2" diameter ...... 8 ft. Specific Gravity D-792 .902 2¼" to 5" diameter ...... 6 ft. Tensile Strength psi D-638 4500 6" and over ...... 4 ft. Elongation at Yield % D-638 20

Tolerances: Modulus of Elasticity in Tension psi D-638 1.9X105 1/4" diameter ...... +.010" - .000" Flexural Strength psi D-790 6000 3/8" - 1" diameter ...... +.005" - .000" Modulus of Elasticity 11/s" 2" diameter ...... +.010" - .000" in Flexure psi D-790 1.8x105 2¼" - 3" diameter ...... +.030" - .000" Impact, lzod ft.libs. D-256 1.0 3¼" diameter and over ...... +.250" - .000" Hardness, Rockwell D-785 90 Hardness, Shore "D" D-676 74 Standard Size Sheets (.060-2") (4" max.).. 48"x96" Hardness, Shore "A" D-676 N/A Thickness Tolerance ...... ±10% Compression Strength psi D-695 5100 Stress Relieved: Shear Strength psi D-732 3500 60.5x61, 49x97, 49x122, 61x122 Thermal Thermal Expansion in./in./°F D-696 4.7x105 Thickness Tolerance...... ±5% Heat Distortion, 264 psi OF D-648 140 Properties Vicat Softening Point OF D-1525 302 Light Weight-Its unusually low specific gravity of 0.89 Thermal Conductivity BTU/hr./ft2!°F/in. 1.62 to 0.91 makes it the lightest of all commercially availa­ Specific Heat BTU/lb./°F .46 Electrical ble thermoplastics. Dielectric Strength volts/mil. D-149 500 Heat Resistance- The ability to withstand constant Dielectric Constant, temperatures of 280° F without deformation or detect­ 60 cps D-150 2.26 able change in mechanical properties makes it an Dielectric Constant, ideal material for products that must be subjected to 1000 cps D-150 2.26 sterilization temperatures of 248° F and over. Power Factor, 60 cps D-150 .0006 Abrasion Resistance-Surface hardness of commer­ Power Factor, 1000 cps D-150 .0006 cial polypropylene is excellent, due in large measure to Volume Resistivity ohms/cm D-257 >1017 its crystalline structure. The abrasion resistance of this Other Flammability Supports material is superior to that of all low cost thermo­ Combustion plastics. Water Absorption % D-570 .03

76

POLYVINYL CHLORIDE,-PVC

Polyvinyl Chloride is one of the most CPVC commonly used thermoplastics. Normally The CPVC molecule has one more chlo­ grey or white in color, PVC is readily asso­ rine atom than the PVC (polyvinyl chloride) ciated with the plumbing industry. How­ molecule. This extra chlorine is responsi­ ever, PVC is becoming widely accepted in ble for the material's high temperature industrial environments due to its wide strength. range of properties. Impact Strength PVC provides excellent weatherability Although high in impact strength, PVC is and resistance to chemicals, moisture and classified as: abrasion. Type I - Chemical Resistant Applications Type 11 - Impact Resistant • Chemical-Oil refining, fertilizer manu­ The slight change in formulation, increas­ facturing, photographic industry, phar­ ing the already good impact strength of maceuticals, petrochemicals. Type I, makes Type 11 a superior material in • Food Processing-Beverage bottling, brew­ impact properties, but slight loss is in­ ing, tobacco industry, water and sewage, curred in chemical resistance. Type 11 PVC dairy industry, distilling. is available on special order. • Power and Electric-Atomic energy, coal Standard Size: mining, electric power industries, battery Sheets ...... 48"x96" manufacturing. Tolerances: • Industrial Plants-Aircraft, glass manu­ 1/16" through 2" ...... ±10% facturing, steel industry, aluminum indus­ Rod ...... 1/4" - 6" try, paper and pulp, textiles. Standard Lengths - 5 ft.-10 ft. Tube- Nominal Size 1/2"-16" Features Standard Lengths - 20 ft. • Chemical Resistance-PVC is inert to attack by strong acids, alkalies, alcohols, and many other chemicals. • Strength-PVC provides both high ten­ sile and high impact strength. • Weather Resistance-PVC is not affect­ ed by direct sunlight, fungi or adverse soil conditions. • Light Weight-PVC weighs 116th that of steel. • Freedom from Toxicity, Odors, Taste­ PVC is approved by U.S.D.A., U.S. Navy and the National Sanitation Founda­ tion. • Non-Porous-PVC machines to close tolerances.

77

PVC-CPVC PHYSICAL PROPERTIES

PVC PVC CPVC ASTM PROPERTIES Normal Impact Hi Impact Hi Temp Test MECHANICAL Specific Gravity 1.38±.02 1.35±.02 1.55 D-792 Tensile Strength@ 73°F, psi 7,500 6,000 8,400 D-638 Compressive Strength, psi 9,600 8,600 - D-695 Flexural Strength @ 73°F, psi 15,000 11,500 15,600 D-790 lzod Impact, ft.lb.fin. notch D-256 @-40°F 0.35 0.49 0.6 @ 32°F 0.47 1.47 1.8 @ 73°F 0.81 15.0 3.0 @ 140°F 1.26 18.40 - @ 180°F 18.30 16.30 - Hardness, Durometer D 80±3 78±3 - D-2240 THERMAL Coefficient of Thermal Conductivity (Cal.) (cm) X 10"4 3.5 4.5 0.96 C-177 2 (cm ) (sec.) (°C) Coefficient of Linear Expansion (see diagram) per °C x 10-5 5.2 9.9 8.0 D-696 per °F x 10-5 2.9 5.5 3.8 Heat Distortion Temperature, ° F @ 264 psi 165 158 230 D-648 Specific Heat, Cal./°C/gm. 0.25 0.25 - Flame Resistance Self-Extinguishing Self-Extinguishing Self-Extinguishing Burning Rate, in./min. Self-Extinguishing Self-Extinguishing Self-Extinguishing Rigid PVC is non-flammable and does not support combustion. Softening Starts, approx. °F 230 230 - Material becomes viscous, ° F 360 360 - Material carbonizes, ° F 450 450 - ELECTRICAL Dielectric Strength, volts/mil. 1,413 1,085 1,250 D-149 Dielectric Constant D-150 60 cps@30°C 3.70 3.90 - 1000 cps @30°C 3.62 3.31 - Power Factor, % D-150 60 cps@30°C 1.25 2.85 - 1000 cps @30°C 2.82 3.97 - Volume Resistivity@ 95°C, ohms/cm/1012 1.2 2.4 - OTHER PROPERTIES Modulus Elasticity in Tension, psi @ 73°F 400,000 320,000 423,000 D-638 Water Absorption, % increase - 24 hrs. @ 25° C 0.05 0.10 0.05 D-570 Light Transmission Opaque Opaque - D-791 Light Stability Excellent Excellent - Effect of Sunlight Slight Darkening Slight Darkening - Color (Standard) Dark Gray Light Gray Medium Gray

78

PVC MITECH® M-104 ConductiveThermoformingSheet Mitech® M-104 Sheet is a conductive, rigid, Mitech® M-104 meets the demanding requirements of thermoplastic, PVC sheet manufactured exclusively by pressure forming, vacuum forming, and thermoforming Mitech Corporation from its proprietary "MAGNEX®AP- operations. Most desired draws can be accomplished, 900" conductive polymer composite. depending on sheet thickness required. M-104 thermoplastic sheet can be machined and can be joined by M-104's excellent permanent electrical conductivity meets adhesive or solvent bonding. minimum static decay requirements of MIL-817058. Thermoplastic M-104 conductive PVC sheet is available in Containers made from M-104 will provide faraday cage black color only, in widths up to 48". Maximum gauge is shielding to enclosed electronic components and devices. 0.500". Minimum gauge is 0.008". Depending on requirements, sheet or roll is available.

M-104 Product Data M-104 thermoplastic sheet is a conductive, rigid, PVC product, with exceptional impact strength and excellent formability. M- 104 can be processed on virtually all thermoforming equipment from high volume, rotary machines to hand-operated presses. Because M-104 is a PVC material, care must be taken in forming to avoid overheating the material. Recommended thermoforming temperature is 300°-370°F.

Physical Properties Typical Test (Units) Value Method Specific Gravity 1.36 ASTM D-792 Tensile Strength (psi) 6300 ASTM D-638 Impact Strength, Notched lzod (ft./lb./notch) 4.0 ASTM D-256

Impact Strength (in./lb./mil./thickness) Gardner Drop Weight >1.0 Flexural Modulus (105 psi) 4.2 ASTM D-790 Flexural Strength (psi) 12000 ASTM D-790 Hardness Shore D 78 ASTM D-2240

Heat Deflection @ 264 psi °F 165 temperature °C 74 ASTM D-648

3 5 Surface Resistivity (ohm/2) 10 - 10 MITECH Static Decay Rate passes mil-8-817058

79

PVC MITECH® M-411 Static Dissipative Sheet Mitech® M-411 static safe thermoformable sheet is made M-411 sheet can be colored and is made to order in rolled from BF Goodrich's Polytron®. This sheet meets the or cut widths to 48 inches and thicknesses ranging from requirements for static safe dissipation according to Mil. .12 to .125 inches. Std. 81705-C and is non-corrosive. Contact Mitech Corporation for additional information, M-411 offers excellent durability and ESD protection even order placement or to request that a sales representative at low humidity because of it's intrinsic alloying system call on you. during compounding. Applications include electronic packaging and storage trays, material handling containers for clean rooms, static safe work surfaces for electronic assembly areas and tapes for surface mount assembly.

M-411 Product Data Electrical Properties

Units Test Value Static Decay 5000 to O Volts Std. 101C @ 15% Rel. Humidity Seconds Method <2.0 @ 50% Rel. Humidity Seconds 4046 <2.0 Surface Resistivity Ohm/Sq D257 1010 -1011 Volume Resistivity Ohm-Cm D257 1011 Mechanical Properties:

Tensile Strength psi D638 5,000

Tensile Modulus psi D638 300,000 Tensile Elongation % D638 100

Flexural Strength psi D790 10,000 Flexural Modulus psi D790 300,000 Notched lzod Impact ft-lb/in D256

@73° F 4 @0° F 1 T HERMAL PROPERTIES:

DTUL (.125 in.) D648

Unannealed @ 264 psi deg.F 150 @66 psi deg.F 156 G ENERAL PROPERTIES:

Flammability@ .062" UL94* V-0

Specific Gravity gm/cc D792 1.30 Hardness Shore D 72

*Based on Laboratory evaluation All information is for natural color

80

RULON®

Rulon® is a plastic material with a low coefficient of corrosion. It immediately found a great number of friction, excellent abrasion resistance, and extreme applications as a bearing material because it required no resistance to corrosion. Rulon® was developed to lubrication and was capable of performing under severe improve the mechanical and thermal properties of temperature (-400° to+ 550°F.) and corrosive conditions. unmodified Teflon® without affecting its unique electrical Rulon® AR has a 1,000-fold increase in wear resistance and chemical properties. Rulon® exhibits a wide range of over PTFE, lower deformation under load, greater improved characteristics over pure Teflon® and has a stiffness and higher compressive strength. lower coefficient of thermal expansion. This characteristic RULON® 142 allows it to operate in a wide continuous service temperature range. Rulon® is practically impervious to Rulon® 142 is a specially formulated linear bearing chemical attack. material designed to improve the performance of sliding surfaces in a variety of machinery. The most common Rulon® J application is linear guideways on the X,Y, and Z axis "RULON®" J, a new all polymeric fluoropolymer slides of CNC and manual machine tools. The unique formulation for a dry bearing material, has been expressly formula of RULON® 142 offers the machine designer and formulated to run against soft materials such as brass, rebuilder a number of operating benefits: 316S.S., aluminum, zinc, plastics and other materials 142 lowers torque which are worn rapidly by existing filled PTFE Eliminates Stickslip-RULON® requirements of the machine and allows for more precise compounds. Rulon® eliminates abrasive and hard and faster positioning. inorganic fillers such as glass, ceramics, graphite, silicates and other commonly used fillers which abrade Vibration Dampening-Noise, chatter, and shock due and scratch soft mating surfaces, or even on occasion to work loads are reduced, while the quality of production some of the harder ones. is improved. "RULON®" J is recommended for use with any mating Operates Lubrication Free-Because of the self­ surfaces which are readily worn by all the usual filled lubricating feature, machine ways and slides are PTFE compounds including stainless steel. The softer protected from galling caused by lubrication failure. surfaces such as brass and never be used with standard filled PTFE compounds, yet "RULON®" J Uniform Friction-Consistant friction under various will loads, temperatures, and other external conditions means give very good service. Although other filled PTFE uniform production. compounds "RULON®" AR are sometimes used with Long Life-Accuracy is maintained on guideways for stainless steel, much improved performances will be extended periods of time due to the wearability of found with "RULON®" J. RULON® 142. "RULON®" J has the lowest coefficient of friction of any Easy Application-Because of the relatively simple filled PTFE. "RULON®" J also maintains the extreme application metho

FRICTION AND W AR OF "RULON®" J vs. 25% GLASS-FILLED PTFE RUNNING AGAINST BRASS, ALUMINUM AND 316 STAINLESS STEEL (1/2" DIAMETER SLEEVE BEARINGS, PV*= 10,000, NO LUBRICATION, WEAR AFTER 150 HOURS}. SHAFT BEARING COEFFICIENT OF WEAR K* FACTOR CONDITION OF MATERIAL MATERIAL FRICTION OF BEARING SHAFT

10 Aluminum "RULON®" J .15 50 X 10- good 25% Glass- Too high Extreme wear very badly Filled PTFE to measure -10 min. scored

Brass "RULON®" J .20 3 X 10-10 excellent 25% Glass- Too high Extreme wear very badly Filled PTFE to measure -10 min. scored

316SS "RULON®" J .15 7 X 10-10 excellent 25% Glass- Extreme wear very badly Filled PTFE .21 in 20 hours scored

81

RULON®

Where To Use RULON® Raw Stock Availability • Low cost, high-performance dry bearings for continuous Compression Molded Rod and Tubing, Sheet service to 20,000 PV or intermittent service to 50,000 PV. Rulon • Low temperatures to -400°F., where oils are useless. 1 " -Rod %" to 13/ 2 4" to 12" Long • High temperatures to 550°F. 1 1 1 -Tube / / x 1" to 27 / 2" x 30 / 2" 4" to 12" Long

• Corrosive substances, non lubricating liquids, high or low 1 humidities. -Sheet 6" x 6" to 24" x 24" / / to 2" Thick • Lubricated applications where wear may occur during Extruded Rod and Tubing starting and stopping. Rulon®

• Oscillating bearings or any case where stick-slip is 1 -Rod / " to 2" Diameter 1" and under 6- undesirable. 8 8' Lengths • Space and weight-saving applications. Over 1", 36-40"

• Where bearing lubrication is undesirable or impossible. Lengths 1 1 Typical Applications -Tube / / X '/2" to 1 2/ " X 2" 1" O.D. and Diameter under 6-8' •CAMS Lengths • Bushings • Rollers • O-Rings • Gaskets • Piston Rings • Thrust Washers

FORMULA COLOR DESCRIPTION Rulon® AR Maroon Standard Rulon® for high wear resistance, low friction, good electrical and chemical properties. Available in all forms. Rulon® J Dull Gold Special Rulon® for certain bearings and seals. Limited chemical resistance, lowest friction and wear, non-abrasive. Rulon® 123 Black Like Rulon® J for operation against soft surfaces, but higher wear, lower cost. Rulon® 7035 Black Used for electrically conductive bearings. Rulon® W-2 Black Specially developed for fresh water bearing and seal applications. Rulon® G-65 Maroon & White Used in wire wound potentiometers and low cost bearings. Rulon® Ultra-liner J Gold Rulon® J stainless steel or bronze mesh laminate for very high load bearing applications.

Rulon® F Green Among the longest wearing Rulon® compounds for bearing applications. Pennlon White A tough, economical bearing material with excellent abrasion resistance. Rulon® 641 White Specifically developed for food and drug contact bearing applications. Made from all FDA accepted ingredients. Rulon® 142 Blue/Gray Bronze, reinforced material for linear bearing applications.

82

RULON® PHYSICAL PROPERTIES

LR AR J 142 641 S ecific Gravity D792 227 2.24 1.95 3.16 2.25 Tensile Strength si D1457 1500 2000 1900 3100 2000 Elongation % D1457 150 175 180 200 150 Deformation Under Load % D621 3 7 3 - 3 Hardness, Durometer D676 60-75 60-75 60 61 60 Thermal Conductivity (B.T.U./hr./sg. ft./°F/in.) Cenco-fitch 2.3 2.3 1.7 - 2.6 Water Absor tion % D570 Non-flammable - 0 0 Flammability (in./min.) D635 Non-flammable - - Non-flammable

Electrical Dielectric Constant (60-1010 cycles) D150 - 2.5 2.4 - -

Dissipation Factor (103-1010 cycles) D150 - .001-.004 .0015 - - Volume Resistivity 15 18 (ohms/cubic centimeter) D257 - 1 X 10 8.2 X 10 - - Surface Resistivity 13 18 (ohms @100% R.H.) D257 - 2.0 X 10 6.3 X 10 - - Arc Resistance (minutes) D495 - 3-4 - - - Dielectric Strength .080 in. D149 - 400-500 200 volts/mil. - - (volts/mil) .010 in. D149 - 900-1100 Chemical Rulon®, like Teflon, has practically universal chemical inertness. Of the chemicals encountered in commercial practice, only molten sodium and fluorine, at elevated temperatures and pressures, show any signs of attack.

83

STYRENE

Crystal PS ia a clear water-white rigid mate­ Polystyrene is soluble in most aromatic and rial. Typical physical property values include chlorinated solvents. It is insoluble in alcohols specific gravity of 1.05, tensile strengths of such as methanol, ethanol, normal heptane 6000to 8000 psi, tensile modulus of 400,000to and acetone. Most foods, drinks, and house­ 500,000 psi, lzod impact of 0.2 to 0.5 ft.lb.fin. of hold fluids have no effect on , but notch, and elongation of approximately 2%. the resins are attacked by citrus-fruit-rind oil, About 40% of all homopolymer PS production gasoline, turpentine and lacquer thinner. is in the crystal grades, but their brittleness prevents use in many applications. Brittleness Applications is overcome by dissolving polybutadiene rub­ General-purpose polystyrenes are used for ber in the styrene during the polymerization knobs, light shields, disposable beverage process. This rubber-modified version com­ glasses and packaging items. High-heat for­ monly is called impact PS. Rubber modifiers mulations are found in radio and TV cabinets, also can be added after styrene polymeriza­ tape reels and appliance parts. Impact grades tion to crystal and impact PS to further change are used in appliances, toys, housewares and the polymer's properties. Impact PS is a trans- specialty items. Foamed polystyrene is used 1 ucent to opaque white material with a specific in wood-replacement products such as gravity of 1.05, tensile modulus of 250,000 to "carved" components for furniture and, in 350,000 psi, tensile strength of 2000 to 5000 extruded form, trim strips and baseboards for psi, lzod impact of 0.6 to 4 ft.lb/in. of notch, residential and mobile-home use. and elongation of 10 to 50%. Applications of the styrene copolymers in­ clude dishwasher-safe housewares, hospital Heat resistance is low compared to that of wares, and . Impact copolymer grades most thermoplastics; maximum recommended are used in small appliance housings, decora­ continuous-service temperature is well under tive trim, and TV components. Glass-fiber­ 200° F. The heat deflection temperature of sty­ reinforced styrene copolymers are suited for rene copolymers is higher by about 20° F than automobile instrument panels. the other polystyrenes. Electrical properties are good at room temperature and are affected Availability only slightly by higher temperatures and vary­ Sheet Sizes: 40" x 72" and 48" x 96" ing humidity conditions. Tolerances: ±10% on thickness Typical Properties of General Purpose and High Impact Styrene ASTM or General Purpose Impact Grades Property UL Test Grades (H. I.) PHYSICAL Specific Gravity ...... D-792 1.04-1.09 1.03-1.10 Specific Volume, in.3/lb...... D-792 26.0-25.6 28.1-25.2 Water Absorption, 24 hr., 1/8" thick (%) ...... D-570 0.03-0.10 0.05-0.6 MECHANICAL Tensile Strength (psi) D-638 5,000-12,000 4,000 Elongation (%) ...... D-638 0.5-2.0 46 Tensile Modulus (105 psi) ...... D-638 4.0-6.0 1.4-5.0 Hardness, Rockwell M ...... D-785 65-80 20 Flexural Strength (psi) ...... D-790 8,000-17,000 6800 Flexural Modulus (105 psi) ...... D-790 4.0-4.7 3.0 Impact Strength, lzod (ft.lb.Jin. of notch) ...... D-256 0.2-0.45 2.0 THERMAL 2 0 Thermal Conductivity (10-4 c al-cm/sec-cm - C) ...... C-177 2.4-3.3 1.0-3.0 Coef. of Thermal Expansion (10-s in./in.-°C) ...... D-696 6.0-8.0 3.4 Deflection Temperature (° F) ...... D-648 @264 psi 190-220 160-200 @ 66 psi 280-230 180-220 Flammability Class* ...... UL-94 HB HB ELECTRICAL Dielectric Strength (V/mil) ...... D-149 Short time, 1/8" Thick ...... 500-700 300-600 Dielectric Constant @ 1 kHz ...... D-150 2.40-2.65 2.4-4.5 Dissipation Factor @ 1 kHz ...... D-150 0.0001-0.0003 0.0004-0.0020 Volume Resistivity (ohm-cm)@ 73°F, 50% R.H...... D-257 1Q17_1019 101s Arc Resistance (s) ...... D-495 60-135 20-100 *V-2, V-1 and V-0 grades are also available.

84

POLYAMIDE-IMIDE-TORLON®

Torlon® is a poly (amide-imide) which exhibits exceptional Only TORLON® engineering polymers offer a physical and chemical properties, and is useful over a wide combination of: temperature range: from cryogenic (-320°F) to 475°F. It has Performance from cryogenic to 500°F superior resistance to elevated temperatures, withstands continuous exposure to 475°F and severe stress conditions; Outstanding mechanical strength and provides better compressive strength and higher impact Low flammability and smoke generation resistance than most other high performance Fatigue strength thermoplastics. Impact strength Torlon's® extremely low coefficient of thermal expansion Creep resistance and high creep resistance delivers excellent dimensional Wear resistance stability over a wide temperature range. It also offers good Low expansion coefficients chemical and radiation resistance. Excellent thermal stability TORLON engineering polymers Resistance to aviation and automotive fluids

high wear 9000 strength resistant series Availabilities Plate 4203L 4347 9040 5030 4301 and Rod Thickness 3/,e" to 1" 7130 4275 others Diameter ¼2" to 2" Width 12" 7330 under Length: 8 ft. nominal Length 48" development

FLEXURAL MODULUS STRENGTH RETENTION AFTER THERMAL VS. TEMPERATURES AGING AT 482°F 250°C

70 ---t-- '\..-15 'a 01-•----+--+ --- !--+'-= '-+--\-'-io !

101 10' Temperature("F) Time,h

TORLON® arade Nominal comoosition Descriotion of orooerties Aoolications

high 4203L 3% Ti02 Best impact resistance, most Connectors, switches, relays, strength 1/,,% fluorocarbon elongation, and good mold thrust washers, spline liners, release and electrical properties. valve seats, poppets, mechanical linkages, bushings, wear rings, insulators, cams, picker fingers, ball bearings, rollers, and thermal insulators.

5030 30% glass fiber High stiffness, good retention Burn-in sockets, gears, valve 1% fluorocarbon of stiffness at elevated temper­ plates, fairings, tube clamps, ature, very low creep, and impellers, rotors, housings, high strength. back-up rings, terminal strips, insulators, and brackets.

7130 30% graphite fiber Similar to 5030 but higher stiff­ Metal replacement, housings, 1% fluorocarbon ness. Best retention of stiffness mechanical linkages, gears, at high temperature, best fasteners, spline liners, cargo fatigue resistance. Electrically rollers, brackets, valves, conductive. labyrinth seals, fairings, tube clamps, standoffs, impellers, shrouds, potential use for EMI shieldina.

7330 Proprietary blend of High stiffness and lubricity. Service requiring high stiffness and carbon fibers and some lubricity, especially sliding fluorocarbons vanes, potential use for EMI shielding. wear 4347 12% graphite powder Good for reciprocating motion or Bearings, thrust washers, wear pads, resistant 8% fluorocarbon bearings subject to high loads at strips, piston rings, and seals. low speeds. Best wear resistance.

4301 12% graphite powder Similar to 4347. Designed for bearing Bearings, thrust washers, wear pads, 3% fluorocarbon use. Good wear resistance, low strips, piston rings, seals, vanes, and coefficient of friction, and high valve seats. comoressive strenath.

4275 20% graphite powder Similar to 4301 with better wear Bearings, thrust washers, wear pads, 3% fluorocarbon resistance at high speeds. strips, piston rings, seals, vanes, and valve seats. 9000 9040 40% glass fiber Similar to 5030 but lower cost. Best Switches, relays, terminal strips, wear series 1% fluorocarbon cost-to-performance ratio. bands, bick-up rings, housings, impellers, brackets, and thermal insulators.

86

Engineering ASTM Method Units 7J eroeerties 4203L 4301 4275 4347 5030 7130 7330 9040 Tensile strength D1708 10' psi -321° F 31.5 18.8 29.5 22.8 0 73° F 27.8 23.7 22.0 17.8 29.7 29.4 26.0 31.8

275° F 16.9 16.3 16.3 15.1 23.1 22.8 25.0 450° F 9.5 10.6 8.1 7.8 16.3 15.7 19.9

Tensile elongation D1708 %

-321° F 6 3 4 3 73° F 15 7 7 9 7 6 6 7 ►

275° F 21 20 15 21 15 14 6 450° F 22 17 17 15 12 11 8

Tensile modulus D1708 10' psi 7.0 9.5 11.3 8.7 15.6 32.2 20.2 73° F - Flexural strength D790 10' psi 0 -321° F 41.0 29.0 54.4 45.0 73° F 34.9 31.2 30.2 27.0 48.3 50.7 40.1 52.0 rn

275° F 24.8 23.5 22.4 20.5 35.9 37.6 31.6 43.6 I 450° F 17.1 16.2 15.8 14.3 26.2 25.2 23.0 38.9

Flexural modulus D790 10'psi - -321° F 11.4 13.9 20.4 35.7

73° F 7.3 10.0 10.6 9.1 17.0 28.8 24.4 21.0

275° F 5.6 7.9 8.1 6.4 15.5 27.2 20.0 20.0 450° F 5.2 7.2 7.4 6.2 . 14.3 22.8 18.7 20.0 - Com ressive strength D695 103 si 32.1 24.1 17.8 18.3 38.3 36.9 30.3 46.7 0

Shear strength D732 10' psi rn 73° F 18.5 16.1 11.1 11.5 20.1 17.3 22.7 00 ---J lzod impact strength (1/8 in) D256 ft•lb/in notched 2.7 1.2 1.6 1.3 1.5 0.9 1.0 1.5 unnotched 20.0 7.6 4.7 9.5 6.4 8.1 Poisson's ratio 0.38 0.33 0.30 0.33 0.40 0.37 0.33 Thermal eroeerties Deflection temperature D648 OF -L 264 si 532 534 536 532 539 540 534 536 0 Coefficient of linear thermal ex ansion D696 1o·• in/in•°F 17 14 14 15 9 5 7 7 ::0 Thermal conductivity C177 Btu•in/hr•ft'•F 1.8 3.7 2.5 3.6 Flammability tt, r- Underwriters Laboratories 94 V-O 94 V-O 94 V-O 94 V-O 94 V-O 94 V-O 94 V-O 94 V-O Limiting oxygen index tt D2863 % 45 44 45 46 51 52 47 0 Electrical eroeerties Dielectric constant D150 z 10' Hz 4.2 6.0 7.3 6.8 4.4 4.3 @) 106 Hz 3.9 5.4 6.6 6.0 4.2 * * 4.6 Dissipation factor D150 10' Hz 0.026 0.037 0.059 0.037 0.022 0.040 106 Hz 0.031 0.042 0.063 0.071 0.050 * * 0.044 Volume resistivity D257 ohm•in 8 X 101• 3 X 1015 3 X 1015 3 X 1015 6 X 101• * * 2 X 101• Surface resistivity D257 ohm 5 X 10'8 8 X 10 17 4x 1017 1 X 1018 1 X 1018 * * 9 X 1017 Dielectric strength (0.040 in) D149 V/mil 580 840 * * 490 General eroeerties Density D792 lb/in' 0.051 0.053 0.054 0.054 0.058 0.054 0.054 0.061 Hardness, Rockwell E D785 86 72 70 66 94 94 107 Water absorption D570 % 0.33 0.28 0.33 0.17 0.24 0.26 0.21

POLYAMIDE-IMIDE TORLON® CHEMICAL RESISTANCE

Chemical resistance of TORLON® 4203L BONDING OF TORLON® After 24 hour exposure at 200°F (93°C) except where Bonding with adhesives noted otherwise. TORLON poly (amide-imide) parts can be joined with commercial adhesives, Chemical Tensile strength Chemical Tensile strength extending design options. It is a good practice to consult the adhesive supplier concerning the requirements of your application. % retained % retained Adhesive choice Acids Aldehydes & ketones A variety of adhesives including amide-imide, epoxy, and cyanoacrylate can be used to bond TORLON parts. Cyanoacrylates have poor environmental resistance and are not Acetic (10%) ...... 100 Acetophenone...... 100 recommended. Silicone, acrylic, and urethane adhesives are generally not Glacial acetic...... 100 Benzaldehyde ...... 100 recommended unless environment conditions preclude other options. Acetic anhydride...... 100 Cyclohexanone ...... 100 TORLON grade Lactic...... 100 Formaldehyde (37%) ...... 100 TORLON 4203L, 5030, 7130, and 9040 are relatively easy to bond. Bearing grades Benzene sulfonic...... 28 Furfural...... 84 4301, 4275, and 4347 have inherent lubricity, and are more difficult to bond. Table 28 Chromic (10%) ...... 100 Methyl ethyl ketone ...... 100 compares the shear strengths of these grades bonded with epoxy, cyanoacrylate, and Formic (88%) ...... 66 amide-imide adhesives. Hydrochloric (10%) ...... 100 Chlorinated organics Surface preparation Hydrochloric (37%) ...... 95 Bonding surfaces should be free of contaminants, such as oil, hydraulic fluid and Phosphoric (35%) ...... 100 Acetyl chloride (120°F) ...... 100 dust. TORLON parts should be dried for at least 24 hours at 300°F (149°G) in a Sulfuric(30%) ...... 100 Benzyl chloride (120°F) ...... 100 desiccant oven (thicker parts, over 1/4 inch (6.3 mm), require longer drying time) to Carbon tetrachloride ...... 100 dispel casual moisture prior to bonding. TORLON surfaces should be mechanically Bases Chlorobenzene...... 100 abraded and solvent-wiped, or treated with a plasma arc to enhance adhesion. 2-Chloroethanol...... 100 Ammonium hydroxide (28%)...... 81 Chloroform (120°F) ...... 100 Adhesive application Sodium hydroxide (15%) ...... 43 Epichlorohydrin ...... 100 For adhesives other than amide-imide, follow the manufacturer's directions. For Sodium hydroxide (30%) ...... 7 Ethylene chloride...... 100 amide-imide adhesive: coat each of the mating surfaces with a thin, uniform film of the adhesive. Adhesive coated surfaces should be clamped under minimal pressure, approximately 0.25 psi (1.7 x 1Q·'N/mm'). The excess adhesive can be cleaned with n­ Aqueous solutions (10%) Esters methyl pyrrolidone (NMP). ** • ·warning! NMP is a flammable organic solvent and the appropriate handling procedures Amyl acetate...... 100 Aluminum sulfate...... 100 recommended by EPA, NIOSH, and OSHA should be followed. Adequate ventilation is necessary when Ammonium chloride ...... 100 Butyl acetate...... 100 using solvents. Ammonium nitrate...... 98 Butyl ...... 100 Curing procedure Ethyl acetate...... 100 Barium chloride...... 100 Amide-imide adhesive should be cured in a vented, air-circulating oven. The Bromine (saturated solution, 120°F) .100 recommended cycle is 24 hours at 73°F, 24 hours at 300°F, 2 hours at 400°F. The parts Calcium chloride...... 100 Ethers should remain clamped until cooled to below 150°F (66°G). Calcium nitrate...... 96 Ferric chloride...... 99 Butyl ether...... 100 Shear strength of TORLON to TORLON bonds with various adhesives Magnesium chloride...... 100 Cellosolve ...... 100 Commercial adhesives were used to bond TORLON parts. The bonds were evaluated* Potassium permanganate ...... 100 p-Dioxane (120°F)...... 100 for shear strength, which appears in Table 28. Sodium bicarbonate ...... 100 Tetrahydrofuran...... 100 Method of cure, handling, and working life of the adhesive are rated in terms of "ease Silver chloride ...... 100 of use." Useful temperature ranges appear in the manufacturers' literature and will vary Sodium carbonate ...... 100 Hydrocarbons with factors such as load and chemical environment. Sodium chloride...... 100 Impact strength of TORLON to TORLON bonds Sodium chromate...... 100 Cyclohexane ...... 100 The impact strengths of bonded TORLON 4203L specimens using the ASTM D256 Sodium hypochlorite ...... 100 Sodium chloride ...... 100 (lzod impact) apparatus were measured in loot-pounds of force required to break the Sodium sulfate...... 100 Diesel fuel...... 99 bond. Epoxy bonds failed at impacts ranging from 0.6 to 14.6; amide-imide specimens Sodium sulfide... . ••·•···············.100 Gasoline (120°F) .. . . ••··•···100 failed at 8.3 to 20 + amide-imide 40% SCF. Sodium sulfite ...... 100 Heptane ...... 100 Bonding for high-temperature applications Mineral Oil... ··················•·········100 Amide-imide adhesive provides high strength bonds at elevated temperature. At

Alcohols Motor Oil.. ·••·•·······················100 350°F (177°G), amide-imide adhesive with 40% SCF withstands lap shear forces over

Stoddard solvent .. ···••··•·100 4000 psi applied to TORLON 4203L/TORLON 4203L bonds. A high-temperature epoxy 2-Aminoethanol...... 9 Toluene .. ····························100 failed at 750 psi under the same conditions. n-amyl alcohol ...... 100 Xylene ...... 100 Shear strength of TORLON to TORLON bonds Epoxy1 Cyanoacrylatei Amide•imide Amide-imide+40¾ SCF n-butyl alcohol... ······················100 psi N/mm' psi N/mm' psi N/mm' psi N/mm' Cyclohexanol ...... 100 Nilriles TORLON 4203L 6000+ 41.4+ 2780 19.2 5000+ 34.5+ 6000+ 41.4+ Ethylene glycol... ······················100 TORLON 4301 2250 15.5 1740 12.0 2890 19.9 Acetonitrile ...... 100 TORLON 4275 3500 24.1 1680 11.6 3400 23.4 Benzonitrile .. ··············•·············100 TORLON 4347 2360 16.3 1870 12.9 2960 20.4 Amines TORLON 5030 4780 33.0 3070 21.2 5140 35.4 Aniline...... 97 TORLON 7130 6400+ 44.1+ 3980 27.4 4750 32.8 n-Butylamine ...... 100 Nitro Compounds TORLON 9040 6100+ 42.0+ 3460 27.4 4530+ Ease of use ,easiest 2 4 Dimethylaniline...... 100 Useful temperature range. Ethylenediamine ...... 7 Nitrobenzene 100 °F -67 to 160 -20 to 21O -321 to 500 -321 to 500 Morpholine ...... 100 Nitromethane...... 100 °C -55 to 71 -29 to 99 -196 to 260 -196 to 260 Pyridine...... 43 • Post-cured TORLON bars, 2.5 x 0.5 x 0.125 inch (6.4 x 1.27 x 0.32 cm) were lightly abraded, Miscellaneous wiped with acetone, then bonded with a 0.5 inch (1.3 cm) overlap. The clamped parts were cured per adhesive manufacturer's recommendations. After seven days at room temperature, bonds were pulled Cresyldiphenyl phosphate ...... 100 on an lnstron® at a crosshead speed of 0.05 inches per minute (0.13 cm per minute). If failure occured outside the·bond area, the process was repeated with progressively smaller bonds areas, to a Sulfolane...... 100 minimum overlap of 0.125 inch (0.32 cm) (in Tables 28 and 29, "+" denotes failure outside the bond Triphenylphosphite...... 100 area at 0.125 inch overlap). 'Hysol EA 9330. Hysol is a registered trademark of Dexter Corporation RESISTANCE TO AUTOMOTIVE AND AVIATION FLUIDS 'Cylok P. Lord Corporation SCF is an Amide-lmide adhesive component available from Amoco Performance Products, Inc. Of particular interest to aerospace and automotive Bonding TORLON parts to metal engineers is the ability of a polymer to maintain its TORLON and metal parts can be joined with adhesives. With proper surface properties after exposure to commonly used fluids. Total preparation and adhesive handling, the resulting bonds will have high strength. In addition, there will be minimal stress at the interface with temperature change. This is immersion tests show TORLON® poly(amideimide) is not because TORLON resins, unlike many other high temperature plastics, have expansion affected by common lubricating fluids at 300°F (149°C}, coefficients similar to those of metals. aircraft hydraulic fluid at low temperatures, and turbine oil, As mentioned in the preceding section, bond strength depends on adhesive selection, even under stress at elevated temperatures. At 275°F and TORLON grade, as well as proper technique in preparing and curing the bond. Table 29 reports shear strength data for TORLON to aluminum and TORLON to steel (135°C}, aircraft hydraulic fluid reduces strength slightly. bonds. Mechanical abrasion alone may not be adequate for preparing steel surfaces­ Tables 12 and 13 summarize the methods and results of chemical treatment of the steel is recommended when service temperature requires use specific fluid immersion tests. of amide-imide adhesive.

88

POLYAMIDE-IMIDE TORLON® COMPRESSION MOLDED

AMOTECH-T™ is the trade name for Amoco's TORLON® FABRICATION OPTIONS proprietary co,npression molding process. This technology allows the manufacture of large shapes from which complex TORLON® poly (amide-imide) can be molded using any of and critical parts can be machined. three conventional molding techniques; injection, compression and extrusion. Each has advantages and AMOTECH-T™ has exceptional thermal stability and limitations. toughness, making it an ideal metal replacement material in rotating equipment. Friction and wear grades provide user Injection molding "operational insurance" when loss of lubrication is critical. TORLON® parts can be injection molded to fine detail. Of For rotating equipment applications, Amotech-T's™ the three methods, injection molding produces parts of the resistance to creep allows designers to take advantage of highest strength. When a large quantity of complex parts is closer running clearances to improve performance, without required, injection molding can be the most economical the risk of galling, common with metal due to expansion. technique due to short cycle times and excellent replication. Part thickness is limited by the flow length versus thickness STOCK SHAPE CAPABILITIES: relationship of the polymer. Thickness is limited to a maximum of inch (15.9mm). Large Round shapes are available in several Amotech-T 5fs formulations. Sizes available range from 2" to over 18" in Extrusion many OD/ID combinations. Minimum radial wall is 1". Custom shapes and formulations are available on special TORLON® polymers can be extruded into profiles and request. shapes such as rods, tubing, sheet, film and plates. Small parts with simple geometries can be economically produced by combining extrusion molding and automatic screw TYPICAL APPLICATIONS: machining. TORLON® 4203L and 4301 are available as rod 1 1 • Labyrinth Seals stock from / 8 to 1 / 2 inches diameter (3.2 to 38.1 mm); tubes 1 from 1 / 2 to 3 inches O.D. (38.1 to 76.2mm); and plates from 3 • Wear Rings / 16 to 1 inch thick (4.8 to 25.4mm). Film as thin as 8 mils is • Thrust Washers also available. • Rod Packing • Bushings Large parts over 5fs inch (15.9 mm) thick must be compression-molded. Tooling costs are considerably lower • Bearings compared with other molding techniques. Compression­ molded parts will generally be lower in strength than • Gears comparable injection-molded or extruded parts. The process • Wear Pads is relatively slow, and increased cycle time boosts part cost. • Rider Bands Compression molded rod in diameter from 7fs inch to 6 inches (22.2 to 152.4 mm) is available from Amoco.

TYPICAL PROPERTIES' (English Units)

High Friction High High Flex Strength &Wear Stiffness Modulus ASTM Grade Grade Grade Grade Prooertv Method Units 4000CM 4340CM 5030 CM 7230CM Density D792 q/cm3 1.36 1.45 1.55 1.51 Tensile Strenoth D1708 103 psi 20.6 12.9 15.1 11.8 Tensile Elonqation D1708 % 13.5 6 6.5 2.6 Flexural Strenoth D790 103 psi 26 19.6 28.0 21.8 Flexural Modulus D790 105 psi 5.64 6 9.95 13.0 Compressive Strenqth D695 103 psi 32.1 18.3 38.3 36.9 Heat Deflection Temp.@ 264 psi D648 OF 532 532 539 540 Coeff. of Linear 6 Thermal Expansion D696 10 1°F 17 15 9 5 Hardness, Rockwell E D785 - 86 66 94 94 Coefficient of PV = 10,000 - .15 - Friction, Kinetic PV = 45,000 - .11 - Wear Factor K PV = 10,000 - 7 - - (10.10 in.3min/ft.lb.hr) PV = 45,000 52 - -

NOTE:' The properties of TORLON poly(amide-imide) resins depend upon the processing method used to prepare the test specimens. The properties shown above were measured using specimens machined from actual compression molded ingots, and are therefore indicative of the properties of AMOTECH Ingots or parts. A section of your AMOTECH Ingot or part can be retained for the measurement of selected properties, if desired. Compression-molded Ingots are not generally post cured.

89

POLYAMIDE-1MIDE TORLON® COMPRESSION MOLDED

AVAILABLE GRADES TORLON® PRODUCTS INJECTION MOLDED STOCK SHAPES TORLON® GRADE DESCRIPTION APPLICATION Injection molded bushings are available in TORLON® 4000 Neat resin with greatest strength grades 4203L, 4301, 4347, and 5030. Other grades are and impact resistance. available on request. Bushings are available in O.D.'s from Typical Applications: 1.0 inch to 2.5 inches, and I.D.'s from 0.75 inches to 2.00 Aircraft and aerospace actuators, inches. housings, insulators, thermal Injection molded KADEL® 1330 bushings are also available isolators, bobbins, etc. in a similar range of sizes. Length of all bushings is 5.0 Applications where strength to inches. weight ratio is extremely Injection molded discs are also available in TORLON® important. grades 4203L, 4301, 4347, and 5030, and KADEL® grade 1330. Discs are available in diameters up to 11.05 inches 4340 Specially designed for bushings and thicknesses to 0.625 inches. and bearings requiring excellent wear resistance. Low coefficient

of friction for dynamic TORLON PRODUCTS EXTRUDED STOCK SHAPES applications. Thermal expansion similar to aluminum. Extruded rod is available in TORLON® grades 4203, 4301, and 5030. TORLON® extruded rod is available in diameters Typical Applications: from 0.25 inches to 2.0 inches, in lengths up to 96 inches. Labyrinth seals, bearings, Extruded plate is available in TORLON® grades 4203 and bushings, thrust washers, wear 4301. TORLON® extruded plate is available in thicknesses pads, wear rings, piston rings, from 3/16 of an inch to 1 inch thick. Plate stock is 12 inches rider bands, rod packing. wide, with lengths available up to 48 inches. Glass filled, providing high 5030 ROD AND TUBE STOCK COMPRESSION MOLDED stiffness at elevated temperatures with low creep. Thermal Radial Tube Stock Part No. Grade 0.0. 1.0. Wall expansion similar to aluminum. 15-1811-XXXX 18 11 3.5 15-1511-XXXX 15 11 2.0 Typical Applications: 15-1509-XXXX 15 9 3.0 15-1508-XXXX 15 8 3.5 Retainer rings, valve plates, 15-1209-XXXX 12 9 1.5 impellers, rotors, insulators, and 15-1208-XXXX 12 8 2.0 15-1204-XXXX 12 4 4.0 vane guides. 15-1109-XXXX 11 9 1.0 15-1108-XXXX 11 8 1.5 7230 Highest flex modulus and 15-1107-XXXX 11 7 2.0 stiffness. Best retention of 15-1106-XXXX 11 6 2.5 15-1105-XXXX 11 5 3.0 stiffness at high temperatures. 15-1008-XXXX 10 8 1.0 Electrically conductive. 15-1007-XXXX 10 7 1.5 15-1006-XXXX 10 6 2.0 15-1005-XXXX 10 5 2.5 Typical Applications: 15-1004-XXXX 10 4 3.0 Metal replacement, housings 15-1003-XXXX 10 3 3.5 mechanical linkages, gears, 15-0907-XXXX 9 7 1.0 15-0906-XXXX 9 6 1.5 splines, valve seats, impellers and 15-0905-XXXX 9 5 2.0 vane guides. 15-0904-XXXX 9 4 2.5 15-0903-XXXX 9 3 3.0

15-0806-XXXX 8 6 1.0 15-0805-XXXX 8 5 1.5 ORDERING INFORMATION 15-0804-XXXX 8 4 2.0 • XXXX-Amotech-T (Torlon®) resin grade. 15-0803-XXXX 8 3 2.5 15-0802-XXXX 8 2 3.0 • Amotech products are priced per inch. 15-0705-XXXX 7 5 1.0 • Sold in 6 inch lengths unless shorter lengths available 15-0704-XXXX 7 4 1.5 from cutoffs. Note: 15-0703-XXXX 7 3 1.0 Amotech-T tube, rod 15-0702-XXXX 7 2 2.5 • Min. order $100. Expediting charge $50. and round stock are 15-0604-XXXX 6 4 1.0 • Resin grade selections should be based on application manufactured by a 15-0603-XXXX 6 3 1.5 proprietary compression 15-0602-XXXX 6 2 2.0 requirements. Call for application technical assistance. molding process. Please 15-0503-XXXX 5 3 1.0 • Custom formulations including injection molding grade refer to product data 15-0502-XXXX 5 2 1.5 for physical property 15-0501-XXXX 5 1 2.0 equivalents are available upon request. information. (F-49980) 15-0402-XXXX 4 2 1.0 • Sizes in bold face type are available from inventory in 15-0401-XXXX 4 1 1.5 friction and wear grades, subject to prior sale. All other 15-0301-XXXX 3 1 1.0 ROOSTOCK Part No. Grade Minimum Diameter sizes and grades are made to order. 15-0100-XXXX 1" 15-0200-XXXX 2" 15-0300-XXXX 3" 15-0400-XXXX 4" ROUNOSTOCK Part No. Grade Minimum Diameter 15-0500-XXXX 5" 15-0600-XXXX 6" 15-0700-XXXX 7" 15-0800-XXXX 8" 15-0900-XXXX 9" 15-1000-XXXX 10" 15-1200-XXXX 12" Available in 1" increments

90

POLYARYLSULFONE (PAS) RADEL®

RADEL Polyarylsulfone offers outstanding thermal toughness in high temperature use, the bonus of resistance, high impact strength, transparency, transparency, and the economy of long life under and hydrolytic stability. stress.

RADEL® Polyarylsulfone is a high temperature material Thermal Properties possessing a superior combination of properties. It The outstanding thermal resistance of RADEL A will competes in high performance applications not only allow long-term exposure of finished parts to elevated with other engineering resins, but with metals, glass temperatures. and ceramics, offering significant advantages. The outstanding properties of RADEL Polyarylsulfone Chemical Properties include: RADEL resins are soluble in a limited number of organic solvents, including methylene chloride, D Thermal stability for extended use dimethyl formamide and dimethylacetamide. Excellent D Excellent toughness hydrolytic stability is a particular attribute of sulfone­ D Superior steam and boiling water resistance based polyarylethers, and RADEL resins are highly D Transparency resistant to mineral acids, alkali and salt solutions­ D Exceptional creep resistance even under stressed conditions at elevated tempera­ D High heat deflection temperature ture. D Good stress-crack resistance RADEL resins have improved resistance to environ­ D Good electrical properties mental stresscracking compared to UDEL® Polysulfone D Injection moldability to close tolerances and significantly better performance than polycarbon­ D Desirable combustion characteristics ate and poly(ester-carbonate). This is especially This unique combination of properties offers a host observed with chlorinated hydrocarbons. The most of new design possibilities. Besides giving a greater aggressive solvents leading to stress crazing or crack­ margin of performance in such areas as toughness in ing include the ketones, esters and aromatic hydrocar­ comparison with other plastics, RADEL Polyarylsul­ bons. The least aggressive systems are the aliphatic fone can take the place of metals in many applica­ hydrocarbons and alcohols. tions. Stress cracking resistance in aggressive environ­ RADEL is suitable for use in electrical and electron­ ments is a function of many factors including molded­ ic parts, withstanding solder temperatures. Possible in stress, applied stress, temperature and exposure applications include printed circuit boards (sheet and time. Whenever questionable conditions exist, specific molded), snap-apart connectors and lamp housings for tests should be run reproducing actual conditions as severe environments. closely as possible. RADEL Polyarylsulfone has high heat deflection temperature (400° F) and good hydrolytic stability; it Hydrolytic Stability resists commonly used acids and bases over a broad RADEL has superior resistance to steam and boil­ temperature range. This combination of properties­ ing water. Hydrolytic stability of injection-molded, 1/8" plus its approval by USDA and FDA for food contact thick test bars was tested by exposure to 270° F uses- makes RADEL Polyarylsulfone ideal for use as steam containing 50 ppm of morpholine. (Morpholine a key component in food service equipment, food and or similar amine chemicals are typically present for medical packaging systems, and many other medical corrosion resistance in steam coming from central applications. supply sources. Such amines can be aggressive The combination of hydrolytic, chemical, and impact toward plastics.) resistance with transparency makes RADEL The molded bars were tested both unstressed and Polyarylsulfone useful for replacing metal and glass with 500 and 1,000 psi constant applied stress. The components in the processing industries...for fabri­ stress was applied via weights attached to one end cated vent pipes in gas-fired water heaters...and for while fixing the other end horizontally as a cantilevered other similar applications. beam. Steam exposure was 30 mins/cycle returning to RADEL Polyarylsulfone's combustion characteris­ room temperature before starting another cycle. tics make it suitable for transportation components Although some crazing was seen, of the three poly­ such as thermoformed housings and structural com­ mers, only RADEL A-200 withstood 1,000 + steam posites. cycles. RADEL Polyarylsulfone gives an extra margin of

91

POLYARYLSULFONE (PAS) RADEL®

IMPACT STRENGTH Tensile impact (ASTM D1822) after steam exposure (see graph below) shows RADEL A-200 maintaining good tensile impact thru 1000 + cycles while poly­ STRESS CRACK RESISTANCE etherimide deteriorated significantly.

CYCLE TENSILE IMPACT vs. STEAM CYCLES APPLIED WHERE FIRST CYCLES 160 STRESS CRACKING TO CAUSE

140 RESIN (PSI) OBSERVED RUPTURE

120 POLYETHERSULFONE 100 RADEL A-200 500 98 1000+

80 1000 98 275 (no rupture) 60 POLYETHERIMIDE Polyethermide 40 500 75 290

1000 50 155 20 Polyethersulfone 189 0-1--...----.,...-.----,, --- r-- 500 110 45 20 40 60 80 100 120 1000 30 NUMBER OF STEAM CYCLES (30 mins.@ 270°G per cycle)

TYPICAL PROPERTIES OF RADEL® POLYARYLSULFONE

TYPICAL VALUES English Units (Standard International in parentheses) ASTM GLASS REINFORCED TEST GENERAL PURPOSE PROPERTIES METHOD A·IUU A•£UU Au·i!lU AU•££U AU•£.iu

MECHANICAL Tensile Strength, psi (MPa) D-638 12,000 (82.7) 12,000 (82.7) 12,500 (86.2) 15,200 (104.8) 18,300 (126.2) Tensile Modulus, psi (MPa) ...... D-638 385,000 (2,655) 385,000 (2,655) 555,000 (3,830) 825,000 (5,690) 1,250,000 (8,620) Flexural Strength, psi (MPa)...... D-790 16,100 (110) 16,100 (110) 21,000 (145) 23,500 (162) 26,000 (180) Flexural Modulus, psi (MPa) ...... D-790 399,000 (2,750) 399,000 (2,750) 590,000 (4,060) 750,000 (5,190) 1,170,000 (8,070) Notched lzod, 1/8" (J/m) ...... D-256 1.6 (85) 1.6 (85) 0.9 (48) 1.1 (59) 1.4 (75) 1 Tensile Impact, ft lbs/in' (kJ/m ) .....D-1822 160 (355) 160 (355) 28 (59) 31 (65) 34 (72)

THERMAL Heat Deflection Temp, 264 psi, (1.84 MPa °F (°C) ...... D-648 400 (204) 400 (204) 410 (209) 415 (213) 415 (213) UL Flammability ...... UL94 V-0@ .023"* V-0@ .023"* V-0@ .031"* V-0@ .031"* V-0@ .031"* (0.58 mm) (0.58 mm) (0.79 mm) (0.79 mm) (0.79 mm)

ELECTRICAL Dielectric Strength, (1/8") volts/mil (kV/mm)...... D-149 383 (15.1) 383 (15.1) 440 (17.3) 440 (17.3) 440 (17.3) Dielectric Constant@ 10' Hz...... D-150 3.50 3.50 3.70 3.84 4.13 Dissipation Factor@ 10' Hz...... D-150 0.0022 0.0022 0.0018 0.0018 0.0018

PHYSICAL Specific Gravity ...... D-792 1.37 1.37 1.43 1.51 1.58 Water Absorption% 24 Hrs...... D-570 1.85 1.85 - - - FDA ...... - Yes Yes No No No Optical, % Haze...... D-1003 - - Opaque Opaque Opaque

"EXPECTED VALUES

92

POLYBENZIMIDAZOLE PBI-CELAZOLE®

Celazole® polybenzimidazole (PBI) resin, is a unique organic ♦ Highest compressive strength of any thermoplastic at polymer which does not burn in air and has extraordinary elevated temperatures high-temperature resistance, along with excellent stability to ♦ Best mechanical properties of any high performance plas- chemicals and hydrolysis. Celazone is ideal for applications tic at elevated temperatures where requirements cannot be met by other resins-at extremely high temperatures, in harsh chemical environ- ♦ Low coefficient of thermal expansion ments, or in applications where durability and wear resis- ♦ Superior fatigue resistance tance are important. Parts molded of Celazole PBI are being ♦ Low coefficient of friction and good wear behavior without used in gaskets, seals, o-rings, and valves in down-hole, geothermal, petrochemical and industrial applications. They added lubricants are also being evaluated in demanding aerospace applica- Extremely high tensile and flexural strength versus other tions requiring outstanding mechanical properties and short- thermoplastics term high-temperature resistance. ◆ Typical Properties of Celazole U-60 - Unfilled, virgin PBI Key Mechanical Proeerties Highest glass transition temperature and heat deflection ProQerty ASTM Method English Value temperature of any thermoplastic (800°F) Tensile Strength D638 23,000 QSi ◆ Elongation D638 3% Tensile Modulus D638 850 kQSi Celazole U-60 Environmental Resistance Ratings Tensile Fatigue,% Temperature Rating @ Days stress to failure at Chemical (OF) 1 million cycles, 1 Hz 35% (8.1 kQSi) 7 30 Flexural Strength D790 32,000 QSi Hydrocarbons Flexural Modulus D790 950 kQSi Xylene Reflux A Compressive Strength D695 Toluene Reflux A at yield (12% strain) 58,000 psi at 10% strain 50,000 Kerosene 200 A ComQressive Modulus D695 900 kQSi Gasoline 200 A lzod Impact Strength, D256 notched 0.5 ft-lb/in Ketones/Aldehydes unnotched 11 ft-lb/in Methyl Ethyl Ketone Reflux A Poisson's Ratio Chlorinated Solvents Methylene Chloride Reflux A Electrical Proeerties Organic Acids ProQertY ASTM Method English Value Dielectric Strength D149 550 V/mil Acetic Acid (Glacial) 200 A Volume Resistivi!J'. D257 8x10" ohm-cm Phenol A A Dissipation Factor D150 200 1 kHz 0.000 Polar Aprotic Solvents 10 kHz 0.003

Dimethylacetamide 200 C D 0.1 MHz 0.034 Alcohols Dielectric Constant D150 Methanol Reflux A A B 1kHz 3.3 10 kHz 3.3 Triethylene glycol 200 A A A 0.1 MHz 3.2

Triethylene glycol 450 A A A 10 GHz 3.5 Strong Bases Arc Resistance D495 1.86 seconds Loss Tangent Sodium Hydroxide 8-12 GHz 0.004 - 0.006 (Caustic(15%)) 200 A B C Weak Bases Thermal Proeerties ProQe ASTM Method English Value Sodium Carbonate(10%) 200 A A A Heat Deflection Temp. Strong Acids 264 si D648 815°F Sulfuric Acid(30%) 200 A C D Glass Transition TemQ. OMA 800°F Hydrochloric Acid A C D Thermal Conductivity 2.8 BTU-in/hr-ft'°F (10%) 200 77°F Hydrochloric Acid(37%) 200 B C D Coefficient of Linear Nitric Acid(10%) 200 B D D Thermal Expansion TMA PhOSQhoric Acid A B D 75-300°F 13x10' in/in°F (35%) 200 390-570°f 18x10' in/in°f Weak Acids Limiting Oxygen Index D2863 58% Acetic Acid(10%) 200 A B B

Aqueous Oxidants Other Proeerties 5% Sodium HyQOChlorite A B B ProQerty ASTM Method English Value 200 SQecific Gravi!J'. 1.3 Water Hardness Boiling Water 212 A B B Rockwell A D785 50 Steam B B B Rockwell M D785 •125 650 Shore D D2240 99 Rating System: A=No Effect B=Small Effect C=Large Effect D=Severe Effect Water Absorption D570 24 hours at 73°F 0.4% Chemical Resistance testing is conducted on tensile and compression test specimens using methodology derived from ASTM D 543. Ratings include tensile and compres- Tribological Properties 03708 Static Friction Coefficient vs. C1018 steel sive strength retention, weight gain or loss, swelling, and hardness changes. Pressure Dynamic Friction Coefficient vs. C1018 steel is ambient except with steam where it is 2200 psi. Wear factor (K) (100 hr test)@ PV=50,000 (P=1000 psi, V=50 ft/min) Total wear (mils) (100 hr test) To the best of our knowledge, the information contained herein is accurate. However, neither Hoechst Celanese Corporation, its parent company, nor any of its affiliates assumes any liability whatsoever for the accuracy or completeness of the information contained herein. Final determination of suitability and whether there is any infringement of patents is the sole responsibility of the user. Users of any substance should satisfy themselves by independent investigation that the material can be used safely. We may have described certain hazards, but we cannot guarantee that these are the only haz­ ards which exist. Celezole is a trademark of Hoechst Celanese.

93

POLYETHERETHERKETONE-PEEK

PEEK is a semi-crystalline, high temperature resistant, Selected Applications engineering thermoplastic with exceptional chemical resistance, fatigue endurance and thermal stability. PEEK • Aerospace/Automotive components also exhibits excellent mechanical and electrical properties. • Military defense applications • Steam cleaning equipment PEEK has a maximum continuous working temperature of • Insulators and connectors 480°F (250°C) and has excellent retention of mechanical • Integrated circuit carriers properties up to 570°F (300°C). In a steam or high pressure • Pump and valve seats/seals water environment, PEEK can be used for thousands of • Housings, rotors and impellers hours at temperatures of 480°F with no significant • Flowmeters degradation of properties. • Bushings, bearings and rollers • Oil drilling tool components Superior chemical resistance has allowed PEEK to work effectively as a metal replacement in extremely harsh PEEK Grades: environments. It is inert to all common solvents and has excellent resistance to a wide range of organic and 450G (natural) heat, chemical and wear resistant. inorganic liquids. PEEK is also exceptionally resistant to 450GL30 (30% glass filled) higher mechanical strength at high levels of alpha beta and gamma radiation and is rated elevated temperatures. UL-94-V-O (.060" tk) with extremely low levels of smoke and toxic gas during combustion. 450CA30 (30% carbon filled) ultimate mechanical strength and wear resistance at elevated temperatures. Summary of Key Properties 450FC30 (lubricated) lower friction, improved wear Chemical Resistance resistance.

PEEK is insoluble in all common solvents and, being semi­ crystalline, has excellent resistance to a very wide range of organic and inorganic liquids.

Wear Resistance PEEK and blends of PEEK with other materials offer excellent tribological properties under a wide range of conditions. High Temperature Performance PEEK Outperforms All Other Plastics In Heat and Chemical Environments PEEK has an estimated continuous service temperature (UL746B method) of 250°C (480°F) with excellent mechanical properties retained to temperatures over 300°C (570°F). P•EEK Hydrolysis Resistance Q) () PPS• C co PEEK can be used for thousands of hours at temperatures t, Torian PAI in excess of 250°C (480°F) in steam or high pressure water "iii • Q a: • Ultem PEI environments without any significant degradation in Polysulfone properties. cii e () .EQ Radiation Resistance .c 0 P•olycarbonate The resistance of PEEK to gamma radiation at high dose levels is exceptional for a plastics material. 250°F 300°F 350°F 400°F 450°F 500°F Flammability Continuous Service Temperature* PEEK has a V-0 flammability rating down to 1.45mm (0.057 in) without the use of additives. (Underwriters' * Unreinforced Laboratories test result). Smoke and Toxic Gas Emission The levels of smoke and toxic acid gas released during combustion are extremely low for a thermoplastic material. Electrical The excellent electrical properties of PEEK remain stable over a wide range of temperatures and frequencies.

94

PEEK-PHYSICAL PROPERTIES

Property Test Method Units 4506 450GL30* 450CA30* 450FC30*

General

Relative Density: (Crystalline) ASTM D792 - 1.32 1.49 1.44 1.48 (Amorphous) ASTM D792 - 1.26 - - -

Filler content - % 0 30 30 30

Water absorption: 24 hr@ 73°F ASTM D570 % .05 0.11 0.06 -

Mechanical

Tensile strength @ 73°F (Break/Yield) ASTM D638 (5mm/min) psi 14,500 (y) 24,650 (b) 32,770 (b) 19,000 (b)

Elongation at break @ 73°F ASTM D638 (5mm/min) % 50 2.2 1.3 3.0

Flexural modulus@ 73°F ASTM D790 psi 594,500 1,450,000 2,900,000 1,175,000 @ 248°F ASTM D790 psi 580,100 1,334,000 2,697,000 1,160,000 @482°F ASTM D790 psi 43,500 435,000 739,500 435,000

Flexural strength@ 73°F ASTM D790 psi 24,650 33,785 51,475 30,450 @248°F ASTM D790 psi 14,500 25,375 37,700 - @482°F ASTM D790 psi 1,800 10,150 15,150 5,220

Shear strength (Ultimate) ASTM D3846 psi 7,690 14,070 14,070 -

Compressive strength @ 73°F ASTM D695 psi 17,110 31,175 34,800 21,750 lzod impact strength@ 73°F Notched 0.01 in radius, 0.14 in depth ASTM D256 ft lbin-1 1.57 1.8 1.59 1.69

Rockwell hardness: R scale ASTM D785 - 126 124 124 - M scale ASTM D785 - 99 103 107 -

Thermal

Melting Point DSC OF 644 644 644 644

Glass transition temperature, Tg DSC OF 289 289 289 289

Coefficient of thermal expansion: < Tg ASTM D696 1o-s OF-1 2.6 1.2 0.83 - > Tg ASTM D696 10-s oF-1 6.0 - - -

Heat distortion temperature, 264 psi ASTM D648 OF 320 600 600 530

Thermal conductivity ASTM C177 Btu-in/hr ft2 °F 1.75 0.43 0.92 0.24

UL continuous use temperature UL746B OF 482 482 482 482 (estimated)

Flammability

Underwriters flammability rating UL94 - V-0(1.45) V-0(1.45) V-0(1.45) V-0(1.45)■ (mm thickness)

Limiting oxygen 0.4 mm thick sample ASTM D2863 %02 24 - - - index: 3.2 mm thick sample ASTM D2863 %02 35 - - 43

• Estimated value (y) = Value at yield (b) = Value at break

95

PEEK - BEARING AND WEAR DATA

Table 1 Tribological Data for Speed= 30.5 m/min (1200 in/min)

20°C(68°F) 200°C(390°F)

Maximum Limiting Coefficient Wear Maximum Limiting Coefficent Wear Load PV of Rate Load PV of Rate Material (kg) (MPa) Friction (µm/hour) (kg) (MPa) Friction (µm/hour) (m/min) (m/min) (a) (b) (c) (a) (b) (c) PEEK 450FC30 210 084 0.11 52 70 77 0.12 152 PEEK 450G 70 357 0.34 303 70 393 0.15 350 PEEK 450CA30 160 813 0.16 88 120 498 0.23 200 'Maranyl' A198 110 298 0.15 250 - - - - (Nylon 6,6 = graphite + glass fibre 'Maranyl' A108 50 216 0.23 - - - - - (Nylon 6,6 + graphite + molybdenum disulphide 'Vespel' SP21 210 -1252 0.08 80 210 -1134 0.08 64 (polyimide + 15% graphite) Polyacetal 50 271 0.24 - - - - - ;cv2wA 170 1010 0.10 40 210 -1023 0.13 38 Resin impregnated carbon) White metal (d) 50 271 0.18 - - - - -

Table 2 Tribological Data for Speed= 183 m/min (7200 in/min)

20°C(68°F) 200°C(390°F)

Maximum Limiting Coefficient Wear Maximum Limiting Coefficent Wear Load PV of Rate Load PV of Rate Material (kg) (MPa) Friction (µm/hour) (kg) (MPa) Friction (µm/hour) (m/min) (m/min) (a) (b) (c) (a) (b) (c) PEEK 450FC30 40 794 0.17 190 40 622 0.141 132 PEEK 450G 8 145 0.58 450 8 147 0.51 150 PEEK 450CA30 22 376 0.28 225 13 445 0.25 - 'Maranyl' A198 10 260 0.34 - 5 99 0.33 - (Nylon 6,6 +graphite+ glass fibre) 'Maranyl' A108 3 71 0.76 - - - - - (Nylon 6,6 + graphite + molybdenum disulphide) 'Vespel' SP21 30 895 0.24 50 20 670 0.21 125 (polyimide + 15% graphite) Polyacetal 5 71 0.34 - - - - - CY2WA 40 '1023 0.18 26 25 746 0.26 75 (Resin impregnated carbon) Carbon filled PTFE 25 447 0.25 250 - - - - White metal (d) 15 265 0.16 - - - - - Oil impregnated porous bronze (d) 25 804 0.09 210 - - - - Graphite porous bronze (d) - - - - 20 403 0.25 75

Notes to Tables 1 and 2 (a) The maximum PV before one or more of the failre criteria (catastrophic increase in friction, temperature, or wear) was exceeded. (b) Average of the mean coefficients of friction at the limiting PV load and at a load 50% of the limitng pV load. (c) Wear rate up to 50% of the limiting PV ????. This figure is only approximate due to errors inherent in the method of measurement. (d) With initial oiling only.

96

PEEK - CHEMICAL RESISTANCE

PEEK exhibits excellent resistance to a wide range of differ considerably from those found in service. especially in organic and inorganic chemicals. the effects of stresses and strains set up during fabrication, and of elevated temperatures. These conditions, particularly The compatibility of PEEK with many chemicals at 20°C those of stress and strain, are difficult to reproduce in the (68°F) has been investigated and the results for laboratory. The table, therefore, should be used only as a unreinforced grades are given in the table. guide, and the user should satisfy himself beforehand of the These results are derived from tests in which unstressed suitability of PEEK for the in-service environment. specimens were completely immersed in a wide range of PEEK also performs outstandingly well in aggressive chemical environments at room temperature. They may environments at high temperatures.

The Chemical Resistance of Unreinforced PEEK 450G at 20°C (68°F)

Chemical Rating Chemical Rating Chemical Rating

Acetaldehyde A Ferric oxide A Paraffin A Acetic acid A Ferric sulphate A Pentane A Acetone A Flourine C Perchloroethylene A Acetonitrile A Formic acid B Phenol (dilute) A Acrylic acid A Formalin A Phenol (cone) C Aluminum sulphate A Phosphoric acid (10%) A Ammonia, anhydrous A Gas (natural) A Phosphoric acid (50%) A Ammonia (liquid) B Gas (manufactured) A Phosphoric acid (80%) A Ammonium hydroxide cone. A Gasoline (sour) A Phthalic acid A Aqua regia C Glycols A Potassium chloride A Potassium hydroxide (dilute) A Benzene A Heptane A Potassium hydroxide (70%) A Benzoic acid A Hexane A Potassium sulphate A Benzaldehyde A Hydraulic Oil A Propane A Bromine/dibromoethane C Hydrochloric acid A Propanol A Bromine (dry) C Hydrobromic acid C Bromine (wet C Hydrofluoric acid C Sodium (hot) C Boric acid A Hydrogen peroxide A Sodium carbonate A Butane A Hydrogen sulphide (gas) A Sodium hydroxide A Sodium hypochlorite A Calcium carbonate A Iodine B Styrene (liquid) A Clacium chloride A Iso-octane A Sulphur hexafluoride (gas) A Calcium hydroxide A Sulphuric acid (up to 40%) A Carbolic acid A Kerosine A Sulphuric acid (40%) C Carbonic acid A Ketones A Carbon dioxide (dry) A Tetraethyl lead A Carbon tetrachloride A Lactic acid A Toluene A Chlorinated solvents B Trichloroethylene A Chlorine (gas) A Magnesium chloride B 1.1.1 Trichloroethane A Chlorine (liquid) C Magnesium hydroxide A Trichlorotrifluoroethane A Chlorobenzene A Maleic acid A Chloroform A Methane A Water A Crude oil A Methanol A Cyclohexane A Methyl alcohol A Xylene A Chromic acid (40%) A Methyl ethylketone A Chlorine water (sat) C Methyl chloride A Zinc chloride A Zinc sulphate A Diethylamine A Nitric acid (10%) A Diethyl ether A Nitric acid (30%) A Dimethylformamide A Nitrobenzene A Diphenyl sulphone B Nitrogen A Nitrous acid (10%) A Ethane B Ethanol A Oxygen A Ethyl acetate A Ozone A Ethyl alcohol A Ethylene oxide A

A = No attack. Little or not absorption. B = Slight attack. Satisfactory use of PEEK will depend on the application. C = Severe attack. PEEK should not be used for any application where these chemicals are present.

97

POLYPLYETHERETHORKETONE-coMPARATIVE CHARTS

PEEK Compared to other High Performance Plastics

Strength and Stiffness

_J 17.5 -1 Torlon 5030 '

(/) - (/ 7.50 Ql C Torlon 4203 'I:: • - t) Tefhtron PPS 4 t . .. 5.00 PEEK Acetale I Ultem- 1000 • Polysulfone Polycarbonate• eNylon 6/6 2.50 I 0.7 0.9 1.1 1.3 1.5 1.7 1.9 2.1 2.3 2.5 Strength (Tensile Strength x 10,000 psi)

High Performance Materials

Maximum Continuous Service Temperature* 600

500

LL. 400 0

:J 300 Ql ea. E 200

100

0

Ql Cl) C C E a 0 w C .2 a. w 0 'S a. *..0 (/) s >- () 0 C >- a. :Ee 0 () a.

• Actual continuous use temperatures may vary within specific application parameters.

98

POLYPLYETHERETHORKETONE-coMPARATIVECHARTS

High Performance Materials Tensile Strength Performance 30000

25000

20000

ci5 Cl 15000

10000

5000

0 0 Q) (/) :,::: 0 C') 0 0 :,::: C a w 0 5 0 C') 0 w C w C') C\J 0 C') w .2 a. 'St" 'St" l{) C\J 0 C C a . ::i a. E C E Cf) . Cf) 0

>, C 2 0 Cf) tu .Q 2 (J>, 0a. 5 5 Ol 0 :Ee c5 (J a. 0 C')

Polymer Groups Performance I

High Performance Plastics PII PAI IPEEK PAS I PES PPS PEI : LCP PSU

1 PTFE Engineering Plastics PVDF I PET PC I PBT I MPPO I PA I POM PE-UHMW - - - - ·PMMA-J------SMA ABS I PP PE-HD Standard PS SAN Plastics I PVC I PE-LD

Amorphous Crystalline

• dimensional stability • heat resistance • electrical properties • chemical resistance • transparency • wear resistance

99

EM®

Ultem® is the high performance material without the SELECTED APPLICATIONS premium cost. With a continuous use temperature of 338°F, • Medical test trials, handles, trays and surgical tools Ultem® bridges the temperature between nylon, acetal and • Transportation industry interior parts requiring flame polycarbonate, and the high temperature/high cost resistance and low NBS smoke evolution thermoplastics such as polyimide and PEEK. • Component parts in silicon wafer chip processing requiring high ionic purity Ultem® is a polyetherimide material most noted for its high • Medical applications requiring resistance to steam strength and rigidity at high temperatures, long-term heat autoclave, hot air, ethylene oxide, gamma radiation and resistance, and stable dimensional and electrical properties. cold chemical sterilization Ultem® also offers broad chemical and flame resistance. • High temperature electrical insulators, connectors, and Not only does Ultem® excel in hot air environments, but in other component parts hot water as well. It's hydrolytic stability is very good with " Metal replacement in a variety of applications 85% of the tensile strength retained after a 10,000 hour SHAPES AVAILABLE boiling water immersion, and 100% tensile strength retention after steam autoclaving 2,000 cycles at 270°F. It is Rod: also resistant to UV and gamma radiation, and offers Ultem® 1000 11 resistance to creep at high temperature and stress levels. 1 / 4 " - 6 dia. Ultem® 2300 Glass reinforced Ultem® provides even greater rigidity and 1 11 dimensional stability. Glass reinforcement gives Ultem® /2" - 6 dia. exceptional strength-to-weight ratio, and increases tensile Length: strength to 24,500 psi, making it one of the strongest 2-8 ft. nominal thermoplastic materials. Plate: Utem® 1000 Ultem Offers You: 1/ " - 2" thick • Strength and modulus at elevated temperatures. 32 Ultem® 2300 • 338°F continuous use temperature 1/4" - 2" thick • Flame resistance with low smoke Width: 12" or 24" • Stable dielectric constant and dissipation factor Length: 48" • FDA compliant (Ultem® 1000 F) • Superior performance in hot water • Excellent finishing characteristics KEY PROPERTIES: • Exceptional strength and modulus at elevated temperatures • 338°F continuous use temperature • Inherent flame resistance with low smoke evolution • Stable dielectric constant and dissipation factor over a wide range of temperatures and frequencies • Broad chemical resistance • Transparent (in thin cross sections) • FDA compliant (unreinforced Ultem® 1000 F)

Temperature, "f 20 300 350 400 250 - 120 32 73'F(23"C) 200 100 "' 24 212'F(100'C) 1 - 150 16 i i .!!! 100 .!!! - - - ., I- 1 month 1 year I- I I I I 8 0 0 50 0 2,000 4,000 6,000 8,000 10,000 Time, hours 0 0 ·25 0 25 50 75 100 125 150 175 200 Temperature, ·c

100

POLYETHERIMIDE-ULTEM® PHYSICAL PROPERTIES

ASTM ULTEM ULTEM ULTEM ULTEM MECHANICAL TEST UNITS 1000 2100 2200 2300 Tensile strength, yield 0638 psi 15,200 16,600 20,100 24,500 Tensile modulus, 1% secant 0638 psi 430,000 650,000 1,000,000 1,300,000 Tensile elongation, yield 0638 % 7-8 5 Tensile elongation, ultimate 0638 % 60 6 3 3 Flexural strength 0790 psi 22,000 28,000 30,000 33,000 Flexural modulus, tangent 0790 psi 480,000 650,000 900,000 1,300,000 Compressive strength 0695 psi 21,900 22,000 28,700 30,700 Compressive modulus 0695 psi 480,000 541,000 809,000 938,000 Gardner impact in-lb 320 lzod impact 0256 notched (1/s") ft-lb/in 1.0 1.1 1.6 2.0 unnotched (1/s") ft-lb/in 25 9.0 9.0 8.0 Shear strength, ultimate psi 15,000 13,000 13,500 14,000 Rockwell hardness 0785 M109 M114 M114 M114 Taber abrasion (CS 17, 1 kg) 01044 mg wt. loss 1000 c cles 10 15 17 20 THERMAL Deflection temperature, 0648 unannealed @ 264 psi (%") OF 392 405 408 410 @ 66 psi (1//) Of 410 410 410 414 Vicat softening point, method B 01525 Of 426 434 428 442 Continuous service temperature index (UL Bulletin 746B) Of 338 338 338 338 Coefficient of thermal expansion (0 to 300°F), mold direction 0696 in/in-°F 3.1 X 10· 5 1.8 X 10· 5 1.4 X 10· 5 1.1 X 1 0·5 Thermal conductivit'.t: C177 Btu-in/h-ft 2-°F .85 1.22 1.43 1.56 FLAMMABILITY Oxygen index (0.060") 02863 % 47 47 50 50 Vertical burn (UL Bulletin 94) V-0@ 0.063" V-0/5V@ 0.075" V-0@ 0.075" V-0@ 0.075" V-0@ 0.075" NBS Smoke, flaming mode(0.060") E662 0@4 min 0.7 1.8 1.3 1.6 Dmax@20 min 30 27 27 20 ELECTRICAL Dielectric strength (1/16") 0149 in oil V/mil 710 700 670 630 in air V/mil 830 770 Dielectric constant @ 1 kHz, 505 RH 0150 3.15 3.5 3.5 3.7 Dissipation factor 0150 @ 1 kHz, 50' RH, 73°F 0.0013 .0014 .0015 .0015 @ 2450 MHz, 50%, RH, 73°F 0.0025 .0046 .0049 .0053 17 17 16 16 Volume resistivity (1/16") 0257 ohm-cm 6.7 X 10 1.0 X 10 7.0 X 1 0 3.0 X 10 Arc resistance 0495. seconds 128 OTHER Specific gravity 0792 1.27 1.34 1.42 1.51 Water absorption 0570 @ 24 hours, 73°F % 0.25 .21 .19 .16 @ equilibrium, 73°F % 1.25 1.20 1.10 .90

The figures shown represent the typical range of values obtained by the resin manufacturer from injection molded specimens and should be used as a guide for selection of glass reinforcement levels. These properties may not be obtained from extruded shapes. All statements, technical information and recommendations contained in this publication are presented in good faith, based upon tests believed to be reliable practical field experience. The reader is cautioned, however. GE Plastics cannot guarantee the accuracy or completeness of this information and it is the customer's responsibility to determine the suitability of GE's products in any given application. ULTEM is a registered trademark of General Electric Company. *ULTEM 2100, 2200, & 2300 are 10, 20 and 30% glass reinforced products.

101

POLYI MIDE-ENVEX® ENVEX® for Demanding Environments Self-lubricating ENVEX® polyimides exhibit low wear rates and high strength at temperature extremes, extending operational life and reducing maintenance costs. High performers at elevated temperatures, ENVEX® polyimides are also recommended for a variety of other applications including nuclear and vacuum environments. They offer radiation, chemical and solvent resistance along with good dimensional stability. Conductive or insulating grades are available. ENVEX® polyimide stock shapes-rods, tubes, plaques or billets-are available for machining. They are also available as finished machined parts; both extruded and intricate direct formed parts molded to a defined geometry. New Ultrasonic Grade ENVEX® E1001 polyimide is now available from Rogers. Made especially for ultrasonic applications, it exhibits excellent attenuation properties over a broad temperature range and exhibits good dimensional stability. E1001 is available as machinable stock shapes, in a variety of sizes.

PRODUCT FEATURES AND APPLICATIONS Selected Product Suggested Temp. Grade Filler Features Aoolications Ranqe Availability ENVEX None High Strength Structural or Continuous use Stock shapes, 1000 insulating temp from extruded, direct cryogenic range formed and to 550°F (288°C\ molded shaoes ENVEX MoS2 Lubricates in Structural and/ Continuous use Stock shapes, 1115 a vacuum or self-lubricating temp from direct formed cryogenic range and molded to 550°F (288°C\ shaoes ENVEX PTFE Very low COF, Self-lubricated Continuous use Stock shapes, 1228 clean lubrication, bearings cryogenic to extruded, direct long wear oscillating and 500°F (260°C) formed and reciprocating molded shapes environments ENVEX Graphite Balance of self- Excellent bearing Continuous use Stock shapes, 1315 lubricating and material and temp from direct formed structural structural part cryogenic range and molded properties to 550°F (288°C) shapes ENVEX Graphite Low coefficient of Unlubricated Continuous use Stock shapes, 1330 thermal expan- bearing temp from direct formed sion holds close applications and cryogenic range and molded tolerances structural parts to 550°F (288°C) shapes

102

POLYIMIDE-E NVEX® PHYSICAL PROPERTIES

TYPICAL PROPERTIES

TEMP. ASTM E1000 E1115 E1228 E1315 E1330 PROPERTY Of METHOD UNITS M DF M DF M DF M DF M DF MECHANICAL Tensile Strength, 73 0-638 10' psi 18.7 7.7 6.8 5.0 6.3 3.0 9.5 4.6 5.6 2.8 Ultimate 500 8.5 3.9 6.2 2.0 3.3 1.1 5.4 2.5 4.9 1.3 Tensile Modulus, 73 0-638 ksi 317 294 359 271 336 163 286 268 289 272 Ultimate 500 216 154 240 117 134 56.9 218 158 240 128 Elongation, 73 0-638 % 9.1 8.7 2.9 5.2 5.9 5.0 4.8 5.5 3.4 4.0 Ultimate 500 13.7 22.2 3.7 10.0 5.7 11.8 8.2 15.8 3.0 8.2 Flexural Strength, 73 0-790 10' psi 24.5 10.7 12.6 6.9 9.8 3.7 18.7 8.1 10.8 4.8 Ultimate 500 9.5 5.1 5.8 3.5 2.1 2.3 8.7 4.3 6.3 3.5 Flexural Modulus 73 0-790 ksi 504 299 580 285 345 177 533 265 566 292 500 287 155 336 146 125 78 339 154 379 128 Compressive Stress 73 0-695 10' psi 30.0 30.3 29.9 24.5 18.5 8.4 25.3 16.2 17.0 9.0 500 8.7 9.9 8.4 4.6 4.6 2.8 8.4 4.3 7.0 3.4 Compressive Stress @ 1% strain 73 0-695 10' psi 4.4 2.4 2.4 1.9 2.3 1.3 2.0 2.0 2.7 0.7 @10% strain 29.1 17.8 27.4 16.7 17.7 8.6 25.3 13.3 - 6.6 @ 1% strain 500 0.6 0.4 0.5 0.15 0.4 0.1 0.4 0.15 0.7 6.7 @10% strain 8.7 6.2 8.3 3.5 4.6 2.4 8.3 3.5 7.5 3.3 Compressive Modulus 73 0-695 ksi 373.4 280.8 427 269.0 300 150.6 393 219.5 360 221.0 500 123 70.3 122 57.4 78.5 34.2 127 58.5 136 53.0 Shear Strength 73 0-732 ksi 12.9 7.86 10.1 7.01 2.9 4.15 8.6 5.75 3.0 3.35 Impact Strength lzod, notched 73 0-256 ft lb/in 0.63 0.41 0.5 0.4 0.6 0.4 0.6 1.6 0.6 0.4 Impact Strenoth lzod, unnotched 73 0-256 ft lb/in 7.2 1.78 3.0 1.0 3.0 1.1 4.24 1.4 2.0 0.9 THERMAL Coefficient of 73-550 0-696 10' in/inl°F 25.3 18.0 22.6 - 26.9 - 22.9 - 21.7 - Linear Expansion -80-73 17.8 18.1 18 - 22.7 - 18.3 - 14.4 - Deformation under 2000 psi load 0-621 % 0.10 0.41 0.20 0.58 0.10 1.05 0.10 0.30 0.54 0.36 Deflection Temperature @264 psi 0-648 OF 580 540 575 540 550 380 570 546 575 570 ELECTRICAL Dielectric Constant 73 0-150 @100 Hz 3.40 - 5.81 - 3.25 ------@ 10,000 Hz 3.34 - 5.40 - 3.20 - - - @ 1,000,000 Hz 3.30 - 4.80 - 3.00 - - - - -

Dissipation Factor 73 0-150

@ 100 Hz ------@ 10,000 Hz 0.0026 - 0.037 0.0020 - @ 1,000,000 Hz 0.0059 - 0.0385 - 0.0503 - - - - - Dielectric Strength 73 0-149 Volts/mil 313 - - - 329 - - - - - Short time 80 mils thick Volume Resistivity 73 0-257 ohm-cm 8.1E+14 - 1.3E+15 - 2.2E+15 - - - - - OTHER PROPERTIES Water Absorption 0-570 % - - 24 Hours 73 0.62 0.65 0.38 - 0.53 - 0.87 - - - 48 Hours 122 0.92 - 1.44 - 0.87 1.14 1.73 - Equil. 50% RH 1.7 - 0.54 - 1.48 - 1.5 - 0.77 - Specific Gravity 73 0-792 1.34 1.17 1.50 1.24 1.51 1.22 1.42 1.19 1.46 1.27 Hardness Rockwell "M" 73 0-785 122 - 111 - 93 - 111 - 103 - Limiting Oxygen Index 0-2863 % 42 - 39 - 38 - 46 - 53 -

* Conductive M=Hot Compression Molded DF=Direct Formed (Cold Pressed and Sintered)

103

POLYIMIDE-VESPEL®

Vespel® performs well with or without lubrication under conditions which would destroy other plastics or severely wear many metals. Vespel® parts function over a wide range of temperatures and stresses. Vespel® retains its outstanding creep, abrasion resistance, and strength under adverse conditions. Vespel® provides a unique combination of the physical properties of plastics, metals and ceramics.

APPLICATIONS • U.S. Navy Uses VESPEL® Adapter in Improved Spline Coupling for Aircraft • VESPEL® Bearing Increases Wear Life in Textile Equipment • VESPEL® Valve Seals Pass Critical Test in Ultra-High Vacuum System • VESPEL® Piston Rings Solve Wear Problem in Gas Compressors

RESIN DESCRIPTION DESIGNATION CHARACTERISTICS SP-1 Unfilled base resin Provides maximum physical properties and best electrical and thermal insulation. SP-21 15%, by weight, graphite filler. Graphite added to provide low wear and friction for bearings, thrust washers, and dynamic seals. SP-22 40%, by weight, graphite filler. Same as SP-21 for wear and friciton plus improved dimensional stability. It has the lowest coefficient of thermal expansion. SP-211 15%,by weight, graphite and Has lowest coefficient of friction over wide range of operating 10% by weight Teflon® conditions. Also, has lowest wear rate up to 300°F. fluorocarbon resin fillers. SP-3 15%, by weight, MoS2 added to provide lubrication for seals and bearings in molybdenum disulfide vacuum or dry environments.

( F} Temo Units Property Method 0 SP-1 SP-21 SP-22 SP-211 SP-3 Tensile Strength, ASTM 73 PSI 12,500 9,500 7,500 6,500 8,200 Ultimate D-638 500 PSI 6,000 5,500 3,400 3,500 - Elongation, ASTM 73 % 7.5 4.5 3.0 3.5 4.0 Ultimate D-638 500 % 7.0 2.5 2.5 3.0 - Flexural Modulus ASTM 73 103 psi 450 550 700 450 - D-790 500 103 psi 250 370 400 200 - Compressive ASTM 73 103 psi 350 420 475 300 - Modulus D-695 Wear Rate, Unlub. in/1000 .25-1.2 .09 .06 .07 .25-.33 PV=25,000 hrs. Friction Coefficient Dynamic* Unlub. .29 .24 .20 .12 .25 Static .35 .30 .27 .20 - Static in Vacuum - - - - .03 Coefficient of E-228 73-572 10·6in/ 30 27 21 30 - Linear Expansion in/°F Dielectric Constant D-150 73 @10•Hz 3.64 13.28 - - - Underwriters Laboratory Flame Rating: 94-VO

AVAILABILITY

Rods Plaques Tubes Bars Direct Formed Rings Standard Size Balls Rods are avail- Plaques are sold in Heavy-walled tubes Bars are 2" x 4" A variety of rings and Balls are available able in several 5 thicknesses, from are available in 33" x 38" in length. discs are offered in in diameters ranging 1 5 different diameters 1// to 2". Face lengths with ODs diameters ranging from /8" to /8" from 1// to 31//. demensions offered ranging from 1.6" from Sfa" to 2 1/2" with Lengths of 9%" are 10" x 10", 10" x to 7.1". Some tubes thicknesses of 1/a" and and 38" are 5" and 5" x 5". are also offered in and 1// available 8" lengths.

104

POLYIMIDE-VESPEL®

Typical Coefficients of Friction-Unlubricated Thrust Bearing Test v=500 fpm v=300 fpm v=1000 fpm v=315fpm Composition Static p=50 psi p=100 psi p=100 psi p:1000 psi SP-21 0.30 0.24 0.17 0.07 0.04 SP-22 0.27 0.30 0.21 0.09 SP-31 0.30 0.24 0.17 0.17

Unlubricated Bearing Characteristics Mild Wear Maximum Regime K Operating Material Filler Cu.ln.Min./Ft.Lb.Hr. Temperature, °F SP-1 Unfilled 100-400 X 10-10 740 SP-21 15% Graphite 33 X 10-10 740 SP-22 40% Graphite 23 X 10 -10 740 PTFE Unfilled 3,000 X 10-10 500 PTFE 15-25% Glass 10-15 X 10-10 500 PTFE 15-25% Carbon 10-15 X 10-10 500 10 PTFE Bronze + MoS2 3-6 X 10- 500 Nylon Unfilled 70 X 10 -10 200-300 Nylon 15% Graphite 15 X 10-10 200-300 Acetal Unfilled 70 X 10-10 200-300 Acetal PTFE 15-20 X 10-10 200-250 Phenolic Unfilled 2,000 X 10-10 350 Phenolic Wood Flour 400 X 10-10 Phenolic Asbestos 1,000 X 10-10 Carbon-Graphite 1-20 X 10-10 200-1,300 Bearing-Bronze 40,000 X 10-10 Bearing-Babbitt 50,000 X 10-10

FIGURE 24 FIGURE 25 MACHINED SP POLYIMIDE DIRECT-FORMED SP POLYIMIDE (.L TO FORMING) LINEAR THERMAL EXPANSION LINEAR THERMAL EXPANSION ASTM D-696 ASTM D-696 Temperature, °K Temperature, °K 300 350 400 450 500 550 300 350 400 450 500 550 I I I I I I I I Avg. Coefficient of Expansion (x1o•) SP-1 1.6 Avg. Coefficient of Expansion (x1o•) - 1.6 - Over 73-572'F (296-573'K) - Over 73-572'F (296-573'K) SP-211 Polyimide in/in °F m/m'K SP-1 Polyimide in/in °F m/m'K SP-1 28 50 1.4 SP-1 and SP-211 30 54 1.4 - SP-21 22 41 -j- SP-21 26 47 SP-22 16 29 SP-22 21 38 SP-211 27 49 1.2 I / 1.2 / '.ISP-211 / if. SP-22 if. / /' .r 1.0 ,I .r 1.0 SP-21 C) / C) ,: ,: / / ."c': ,I ."c': V//I () () ,I / iij 0.8 , iij 0.8 Ii ,: I ,: .; 0 }/ ,I 0 /• / .; ·0 ·0 ,: ,: .; , /; / / .; SP-22 0.6 0.6 L,., ,I i5"E i5"E .; ,I ff .; 0.4 /2 0.4

.; '/ .;

.,I.•., ) .; 0.2 0.2 f'.;' .; /H J[.; ,, 0 100r 200 300 400 500 600 0 100 200 300 400 500 Temperature, °F Temperature, °F

105

PQLYIMIDE-VESPEL® Chemical Resistance

Chemical Effects

Vespel® SP parts perform well in a variety of chemical TABLE3 environments. The tensile strength data shown in Table 3 were determined using exposure tests patterned after ASTM % Tensile Method D543-67, "Resistance of Plastics to Chemical Strength Reagents." Time Retained by Chemical Media Hrs. SP-1 Organic Solvents OF OK

In general, exposure to solvents for prolonged periods over Organic Solvents a wide temperature range does not affect the mechanical M-Cresol 400 477 1,000 75111 and dimensional properties of Vespel® parts. Chlorinated o-Dichlorobenzene 355 452 1,000 100 and fluorinated solvents such as FREON® fluorocarbon, can Diethyl ketone 210 372 1,900 100 be used for surface cleaning of Vespel® parts as long as Ethanol 210 372 1,900 100 adequate ventilation exists. Nitrobenzene 420 488 1,000 8511) Perchloroethylene 210 372 1,900 100 At elevated temperatures some hydrocarbon solvents Toluene 210 372 1,900 100 containing functional groups, such as M-cresol and nitrobenzene, can cause SP polyimide parts to swell; however, Vespel® parts are suggested for service in a variety Industrial Fluids of industrial fluids (fuels, oils, lubricants) at elevated Hydraulic Fluid temperatures. Generally, Vespel® parts exposed to the fluids ("Skydrol"), detailed in Table 3 exhibit no significant change in Polyphosphate dimensions or mechanical properties. However, the ester. 248 393 1,000 100 compositions of industrial fluids differ among manufacturers JP-4 Jet Fuel 210 372 1,900 80 and can vary over time with any single manufacturer. Testing Jet Engine Oils 500 533 600 60(90)121 is recommended for each proposed use of Vespel® parts to (MIL L7808 G, Type 2) 500 533 1,000 30 60)121 provide quantitative guidance on the effect of the specific Mineral Oil 392 473 1,000 70 90)12) environment. Silicone Fluid 500 533 1,000 70 85)12)

Aqueous Media Tricresyl phosphate SP polyimide parts can be exposed to water up to 212°F (oil additive) 500 533 1,000 80 (373°K), provided the stresses are low enough to take into account the reduced mechanical properties. At 212°F Acids (373°K), the tensile strength and elongation of SP polyimide Acetic, 15% 210 372 1,900 20 parts are reduced to 45% and 30% of the original values, Hydrochloric, 38% 73 296 120 70 respectively, in about 500 hours, at which point they level Hvdrochloric, 5% 210 372 1,900 15 out. Some of the reduced tensile properties caused by Nitric, 70% 73 296 120 40 moisture absorption may be restored by drying. Bases FIGURE 26 Sodium Hydroxide, MACHINED SP POLYIMIDE TYPICAL FATIGUE 5% 73 296 120 55 RESISTANCE vs. TEMPERATURE REVERSED TENSILE AND COMPRESSIVE STRESS@ 1800 CYCLES/MIN (30 Hz) Temperature, °K Oxidizing Agents 300 350 400 450 500 Nitroaen Tetroxide 73 296 120 60 I I I I I

50 7

SP-1 { (1) Swelling. 6 " 40 (2) SP-21 polyimide (15% graphite-filled). ' " SP-21 5 r-:< t, t ,,. "Yci "e 'qi' . 30 c..., C. 'iii ":Yc1. ,. Fq .:,:."' 4 6 '-' :;; ui ·v,-ql,· V- '- ,' ' ,, "e' ' ui Cl) 20

10

i---- o ------1 0 100 200 300 400 500 Temperature, °F

106

POLYPHTHALAMIDE - PPA- AMODEL®

Amodei® is a family of high temperature, high performance thermoplastics based on polyphthalamide (PPA) chemistry. These semi-crystalline polymers have excellent physical and mechanical properties, outstanding dimensional stability, and high temperature handling capability. Because of its unique bal­ ance of properties, Amodei finds acceptance in a broad range of applications and markets.

Standard Grades of Amodei GRADE DESCRIPTION KEY PROPERTIES TYPICAL APPLICATIONS

AD-1000 Unreinforced Excellent chemical resistance Gears, hose and tubing, seals, Good wear and friction properties wire and cable A-1115 HS Glass Reinforced High Strength and stiffness Automotive under-the-hood parts, A-1133 HS High thermal properties gears, bearings and industrial parts A-1145 HS Excellent chemical resistance A-1230 HS Mineral Reinforced Low warp, good dimensional stability Decorative parts, plumbing fixtures A-1240 HN and excellent surface appearance and reflectors; chrome platable A-1340 HS Mineral/Glass Reinforced Lower warp than glass Small engine components, power Higher strength and stiffness than mineral tools, ignition components ET-1000 Impact Modified High toughness and impact combined Power tools, recreational equipment, with high strength and stiffness clips and fasteners, caster wheels Low moisture sensitivity

AF-1115 VO Flame Retardant UL 94 VO @ 1/32" Electrical components: connectors, AF-1133 VO Glass Reinforced VPS, IR processable switches, sockets, circuit breakers AF-1145 VO High strength and stiffness

High Temperature Capability Amodei

Melting Point 590°F (310°C)

Heat Deflection Temperature (264 psi)11l 545°F (285°C)

Glass Transition Temperatur1e2l 274°F (135°C)

Continuous Use Temperature (5000 hours)1"1 365°F (185°C)

High Mechanical Properties<1l Amodei

Tensile Strength 32,000 psi (220 MPa) Flexural Strength 45,000 psi (310 MPa) Flexural Modulus 1,650,000 psi (11,400 MPa) Notched lzod Impact Strength 2.4 ft-lb/in. (130 J/m)

(1) Amodei A-1133 HS (2) As Determined by ASTM D-4065, Method C (3) As Determined by ASTM D-3045

1 Comparative Properties( Amodei demonstrates exceptional performance advantages when compared to other well known ther­ moplastics.

ASTM AMODEL 30% GF 30% GF 33% GF 30% GF 30% GF 25%GF PROPERTY* METHOD UNITS A 1133 HS PET PPS NYLON 6,6 PEI PBT ACETAL

Heat Deflection Temp. 264 psi D-648 OF 545 435 500 480 410 405 325 Tensile strength 73°F D-638 psi 32,000 23,000 16,000 27,000 24,500 17,300 18,500 Flexural Modulus 73°F D-790 psi 1,650,000 1,300,000 1,400,000 1,300,000 1,300,000 1,100,000 1,050,000 Notched lzod Impact Strength D-256 ft-lb/in 2.4 1.9 1.0 2.0 2.0 1.6 1.6 Specific Gravitv D-792 Q/cc 1.43 1.56 1.57 1.38 1.51 1.53 1.61 Water Absorption 24 hr. 73°F D-570 % .21 .05 .05 .7 .18 .08 .29

*Dry as Molded

107

POLYPHYNYLENE OXIDE - (PPO) NORYL®

Noryl® is composed of modified polyphynylene oxide and AVAILABILITY has the unique ability to perform at high and low temperatures without sacrificing key properties. Noryl® can EN185 EN265 SE-1-GFN3 Rod N/A 1/a"-8" 1//-6" remain stable under load in temperatures as low as -40°F .030"-.250" .030"-6" 1/a"-4" Sheet/Slab and as high as 265°F. Noryl® combines excellent electrical N/A Custom Custom Tube itsproperties high impact with strengthlow moisture and absorptionpredictable and mechanical also maintains N/A Custom Custom Profiles strength over a wide range of temperatures. Noryl® is EN265SLAB available in several grades including the SE-1-GFN3, which is 30% glass filled. The other grades available are EN-18 STANDARD SIZES: which has a heat resistance of 185°F, and EN-265 which 3/15" - 1// : 48" X 96" has a heat resistance of 265°F. These different grades 3/a"-2": 12" X 48"; 24" X 48": 48" X 96" afford the designer an expanded range of strength, heat 21//-4": 12" X 48" resistance and toughness. Noryl® SE-1-GFN3 is generally TOLERANCES: recommended for applications requiring U.L. V-0 rating, and Length and Width: +.250"-.000" the high mechanical strength and dimensional stability of Thickness: ±10% glass-reinforced resins. SE-1-GFN3 SLAB GENERAL PROPERTIES • Premium performance and a U.L. V-1 rating STANDARD SHEETS: • UL temperature rated at 105° C 1/a" thru 4" thick-12" x 48" • Stress relieved-excellent machineability 1/a" thru 3/a" thick- 24" x 48" • Outstanding electrical characteristics Available on Special Quotation: • Outstanding thermal properties 1/a" thru %" thick-30" x 60"; 48" x 96" • High resistance to creep Tolerances: Thickness ±10% • Long term dimensional stability • Outstanding hydrolytic stability SUGGESTED APPLICATIONS: • FDA approved Water Distribution Water softener valves PROPERTIES OF NORYL® RESINS Pump components ASTM EN185 EN265 SE-1-GFN3 Ball cocks and tank trim (30% glass filled) Phvsical and Mechanical Beverage dispenser components Specific Gravity, 73°F D-792 1.06 1.06 1.36 Automotive/Transportation Water Absorption, % Specialty hardware 24 hrs. @ 73°F D-570 0.06 0.06 0.06 Tensile Strength, psi@ 73°F D-638 6,500 8,000- 17,800 Bezels, housings 9,600 Gauges and instrument parts Flexural Strennth, nsi @ 73°F D-790 8,000 13,500 20,000 Coil forms and bobbins Flexural Modulus, psi Fender extensions @73°F x 103 D-790 340 360 1,100 Mass transit seat housings lzod Impact Strength ft.lbs.fin. notch @ 73°F D-256 7.0 5.0 2.3 Appliances/Business Machines -40°F 3.0 2.5 N/A Housing (portable mixers, calculators, Rockwell Hardness D-785 R113 R119 L108 computers, electric knives) Thermal Coffee pots and components Heat Deflection Temperature Attachments (vacuum sweepers and floor polishers) D-648 185 265 275 (264 DSil, °F Plated and vacuum metallized parts Coefficient of Thermal (decorative and functional use) Expansion, in./in.i°F (-20° to 150°F\ x 10-s D-696 4.1 3.3 1.4 Medical Electrical Surgical instruments Dielectric Constant (50% R.H., 73°F@ 60 ens\ D-150 2.80 2.69 3.15 Vaporizer parts Dissipation Factor Utensils, trays, basins (50% R.H., 73°F@ 60 ens\ D-150 0.0004 0.0007 .0020 Electrical Components Volume Resistivity, Terminal boards drv ohm, cm. 73°F D-257 10" 17 10" 10 Relay cases Surface Resistivitv, ohm ner sn D-257 1015 10" 1017 Dielectric Strength Radio and TV components /18" samole \ volts/mil D-149 630 500 530 Connectors and live guards U.L. Subject@ .060" 94 V-1 94 V-1 94 V-0 Motor controls and wiring devices .125" 94 V-0 94 V-1 94 V-0 Radiant Panel @ .125" E-162 50 Other Steiner Tunnel @ 160" E-84 170 Mist and scrubber eliminator blades 250"

108

POLYPHENYLENE SULFIDE (PPS)-FORTRON®

Fortron® PPS, a high-performance thermoplastic material, is replacing metals, thermosets and other thermoplastics in demanding applications. Fortron is often selected over these materials •because it provides the following benefits that other materials cannot provide:

Metal Replacement Fortron® PPS is further distinguished from highly branched PPS products by the following performance advantages: • Chemical resistance/ corrosion resistance • Opportunity for parts consolidation • Higher elongation and impact strength • Cost savings • Higher weld line strength • High strength-to-weight ratio • Lower ionic impurities in base resins and filled products • Color-coding possible (natural color is light tan) • A natural color of light beige for the Fortron® PPS base resin for easier coloring Replacement of Other Thermoplastics Most designers choose Fortron® PPS because it • Truly superior chemical resistance at elevated demonstrates a valuable combination of properties relative temperatures to the load-bearing capabilities and dimensional stability • Inherent flame resistance without additives. (UL94 V-O when exposed to chemicals and high-temperature grades) environments. • Outstanding retention of mechanical properties under continuous use up to 428°F (220°C) Reinforcements and Fillers • Holds dimensional stability over wide variations in temperature and moisture When fillers, such as glass fibers, minerals, or mixtures of • Superior electrical insulation properties these, are added to the base resin, the load-bearing capability, represented by the heat distortion temperature General Characteristics of Fortran® PPS (HOT), is also raised. The HOT of Fortron® unreinforced PPS is generally 221°F (105°C) at 264 psi, while that of a The structure of Fortron® PPS polymer contributes to the reinforced Fortron® PPS is 500+°F (260+0 C). Because of following properties: this added value and Fortron® PPS's affinity for fillers, the • High thermal stability majority of PPS applications use glass-reinforced or • Excellent chemical resistance mineral/glass-filled systems. • Inherent flame resistance • Excellent electrical properties

Applications Benefits

Automotive and Related • Cost savings through parts consolidation • Intake manifolds • High strength-to-weight ratio • Pumps (water, oil and fuel) • Resistance to corrosive alternative fuels • Injector systems • Temperature resistance • Fuel rails • Viscosity consistency/ processing ease • Connectors • Creep resistance

Electrical/Electronic • High density connectors • Inherently flame retardant (V-O) grades • Burn-in sockets • Dimensional stability • Electrical housings/ chassis • Intricate part designs possible • Vapor phase soldering temperatures up to 500°F (260°C) • Low ionic impurities/ good electrical insulator

Industrial/Mechanical • Blower and pump parts • Corrosion resistance • Housings • High temperature performance I continuous use • Impellers temperature up to 428°F (220°C) • Flowmeters • High strength-to-weight ratio • Sensors (temperature and level) • Creep resistance • Valves and fittings • Cost savings through parts consolidation • "Down hole" oil-field parts • Dimensional stability

109

POLYPHENYLENE SULFIDE (PPS)-FORTRON®

Fortran® (PPS) - Typical Properties

Mineral ASTM Unreinforced 40% and Glass- Property* Method Units Polymer Glass-Fiber Fiber

Physical Specific Gravity D792 - 1.4 1.6 1.8 Water Absorption 24 hr. Immersion D570 % 0.03 0.03 0.03 Mechanical @ 73°F (23°C) Tensile Strength D638 psi 12,500 25,000 21,000 Elongation D638 % 3-6 1.7 1.35 Flexural Strength@ 5% Defection D790 psi 21,000 35,000 30,400 Flexural Modulus D790 psi 600,000 1,900,000 2,000,000 Rockwell Hardness D785 M-Scale 93 100 100 lzod Impact Strength: notched D256 ft-lb/in 0.5 1.6 1.2 unnotched D256 ft-lb/in 6-12 11 7 ** Multiaxial Impact@ 7.33 ft/sec D3763 ft-lbs 1-4 7 6 @ 11.35 ft/sec D3763 ft-lbs 1-4 7 6 Thermal Heat Deflection Temperature:@ 66 psi D648 OF(OC) 392 (200) 536 (280) 536 {280) @264 psi D648 OF(OC) 221 (105) 509 (265) 509 (265) ***Continuous Use Temp. elec./ mech@ 1/8" - oc - 220/200 220/200 UL Flame Class rating - UL94 - V-0@ 1/64" V-0@ 1/32" CSA Rating: @ 1.8mm - - - ADO ADO @0.84mm - - - 0.6V-O 0.6V-O Coefficient of Thermal Expansion (x1Q-5): Flow/Transverse @ -30° to 80°C D696 oc-1 4.2/4.0 2.1/4.2 1.9/3.2 Flow/Transverse @ -120° to 240°C D696 oc-1 18/8.0 4.8/9.0 3.6/8.0 Electrical Dielectric Strength @ 0.125 in D149 V/mil 450 450 450 Dielectric Constant @ 73°F: 1 kHz D150 - 3 3.5 3.8 1 MHz D150 - 3 3.5 3.8 Dissipation Factor@ 73°F: 1 kHz D150 - 0.001 0.001 0.001 1 MHz D150 - 0.0009 0.001 0.0008 Volume Resistivity D257 ohm-cm 1Q16 1 Q16 1 Q16 Arc Resistance D495 secs. 124 134 156 Comparative Tracking Index - UL 746A - Volts 150 150

* Test specimen mold temperature (275°F) ** Multiaxial impact, values are total energy to break **' Electrical/Mechanical with impact

110

POLYPHENYLENE SULFIDE (PPS)-RYTON®

Increased customer demand for high performance and cost-effective engineering materials has led to a new generation of sophisticated polymers, coinciding with significant advances in processing and fabricating technology. Ryton® polyphenylene sulfide (PPS) compounds from Phillips 66 Company have more than 15 years of proven performance, and continue to be some of the most versatile, advanced and cost-effective materials used for the most demanding applications today. The stable aromatic chemistry of Ryton PPS yields several very attractive benefits including: • Remarkable endurance at very high temperatures • Outstanding resistance to a broad spectrum of aggressive chemicals • Inherent flame retardance without flame retardant additives • Stable dielectric and insulating properties • An affinity for most fillers and reinforcements (so specific market applications can be tailored to meet requirements accurately) While each of these features is beneficial individually, Ryton PPS combines them all in one material at a moderate price. Except for Ryton PPS, that property combination is available only in a few exotic polymers, at high cost to the customer. Nominal Engineering Properties of Ryton® PPS

Bearing Glass Filled Mineral & Glass Filled Grade Property ASTM R-4 A-200 R-7 R-10 BR428 Mechanical Tensile Strength, Ksi* D638 20.5 16.0 16.5 14.7 22.5 Elongation, % D638 0.9 1.0 0.7 0.7 - Flexural Strength, Ksi D790 28.0 23.0 25.6 22.0 33.0 Flexural Modulus, Msi** D790 1.9 1.7 2.5 2.4 1.9 Compressive Strength, Ksi D695 26.0 23.7 23.0 18.5 - Modulus of Elasticity, Msi D638 2.2 1.9 2.5 - - lzod Impact Strength,

¼ in. specimen, ft·lbf/in Notched D256 1.5 1.0 1.3 1.0 1.3

Unnotched 5.5 4.5 3.6 2.8 11.0

Thermal

Heat Deflection Temperature

@264 psi, °F D648 >500 >500 >500 >500 >500

200/220 200/220 200/220 200/240 UL Temperature Index, °C - Flammability Rating, UL 94 V-0/5V V-0/5V V-0/5V V-0 - Electrical Dielectric Strength, V/mil D149 450 486 450 400 - Dielectric Constant, 78°F 1 kHz D150 3.9 4.3 5.1 5.8 - 1 MHz 3.8 4.2 4.0 5.8 - Dissipation Factor, 78°F 1 kHz D150 0.002 0.003 0.058 0.030 - 1 MHz 0.0014 0.007 0.0088 0.029 - 16 15 15 15 16 Volume Resistivity, ohm-cm D257 1 X 10 1.4 X 10 5 X 10 5 X 10 1.5 X 10 Arc Resistance, sec D495 34 124 167 116 140 Arc Tracking Rate, in/min UL 746A 7.1 12.9 0 4.8 - Comparative Tracking Index, V UL 746A 130 160 225 220 - Insulation Resistance, ohm 11 10 12 8 11 (90°C, 95% RH, 48 hrs) 1 X 10 1 X 10 1 X 10 2 X 10 3 X 10

Other Density, g/cc D792 1.65 1.60 1.90 2.00 1.65

Water Absorption,% D570 0.05 0.05 0.03 0.07 -

Wear Rate*** in/hr D3702 - - - - 5.75 X 1Q·5

D3702 .44 Coefficient of Friction*** - - - • Ksi = 10' psi •• Msi = 10' psi ••• Test Duration -100 hr; Specimen Load - 50 lb (250 psi); RPM -36; Temperature-ambient; Test Fluid- Dry; Test Surface-1018 Steel; PV = 2500.

111

POLYPHENYLENE SULFIDE- TECHTRON® (PPS)

TechtronTM brand polyphenylene sulfide thermoplastic PPS TECHTRON® shapes are resistant to a wide variety of chemicals, while Test remaining stiff and strong, over a broad temperature range. Method There are no known solvents for Techtron™ below 392°F Prooertv Units ASTM Techtron (200°C), and it can be used at temperatures as high as Mechanical 425°F (218°C) continuously. Specific Gravity 0792 1.35 Techtron™ fills the demand for a product which closes the Tensile Strength 73°F psi 0638 12,000-14,000 gaps in PEEK's resistance to chemical environments. Elongation 73°F % 0638 20-25 Techtron's physical properties are comparable in application Flexural Strength 73°F psi 0790 21,000 temperatures 50°F below the capability of PEEK. Flexural Modulus of Elasticity psi 0790 540,000- Polymer's production and stress relieving techniques also 600,000 overcome the inconsistency, warpage and cracking Shear Strength 73°F psi 0732 9,250 problems of compression molded PPS which have restricted Compressive Strength the use of the material in machined parts. 10% Def. psi 0695 18,000 KEY PROPERTIES: Compressive Modulus • Exceptional chemical resistance of Elasticity 73°F psi 0695 450,000 • 425°F (218°C) continuous use temperature Hardness, • High temperature stiffness retention Rockwell 73°F 0785 M93 • High temperature hydrolysis resistance Tensile Impact • Superior dimensional stability 73°F Ft.lb.fin.' 01822 75 • Inherent flame resistance (UL 94-V-0) Thermal • Not brittle like compression molded PPS shapes Coefficient of Linear • Lower moisture absorbtion than PEEK Thermal Expansion In.fin.IF 0696 2.8 X 10·5 APPLICATION AREAS: Deflection Temperature 264 psi OF 0648 221 • Chemical Processing Melting Point OF 0789 540 -Pump and valve components Continuous Service -Oil field parts -Housings Temperature in Air OF -Impeller diffusers (Maximum) 425 -Chemical tower packing Electrical -Tubing Dielectric Strength Short Time Volts./Mil. 0179 540 • Scientific Instrumentation Volume Resistivity OHM-CM 0257 4.5x10·" -Fingertights, ferrules, columns, seals Dielectric Constant -Tubing 60 Hz 0150 3.0 -Component parts Dielectric Constant • Electrical/Electronic 10' Hz 0150 3.0 -High temperature insulators, connectors Dissipation Factor -Brush holders, coil bobbins 60 Hz .0013 -Integrated circuit carriers, boards Dissipation Factor -Relay components 10' Hz .0010 -Business machine parts Chemical (Overview-details inside) -Housings Water Absorption -Applications requiring resistance to high temperature Immersion 24 hrs. % 0570 .01 soldering techniques Acids, Weak 73°F A • Miscellaneous Acids, Strong 73°F A -Aerospace components Alkalies, Weak 73°F A -Appliance parts Alkalies, Strong 73°F A -Automotive parts Hydrocarbons -Baking ovens in food processing -Aromatic 73°F A -Conveyer components in paper manufacturing Hydrocarbons AVAILABILITIES: -Aliphatic 73°F A Rod Ketones A 3 Diameter: /8"- 3" and intermediate Ethers A Length: To 2-%"-8 foot nominal Esters A Over 2-%"-4 foot nominal Alcohols A Sheet/Plate 1 Inorganic Salt Solutions A Thickness: / 4"- 2" and intermediate Width: 12" Continuous Sunlight L Length: 48" KEY: A = Acceptable Service L = Limited Service U = Unacceptable Service

112

POLYPHENYLENE SULFIDE - TECHTRON®

PPS CHEMICAL RESISTANCE GUIDE There is no known solvent that dissolves Techtron™ PPS at temperatures below 392°F (200°C}. Some organic solvents at high temperatures cause Techtron™ PPS to swell, resulting in a slight reduction in mechanical strength. Environments such as long-term contact with water, acids and caustic solvents at temperatures above 212°F (100°C} may also affect mechanical strength slightly. Techtron™ PPS is not resistant to oxidizing acids such as hot nitric acid. In general, time, pressure, temperature, concentration, degree of agitation and presence of impurities influence chemical resistance and should be considered when assessing requirements. Pretesting of the Techtron™ is recommended in all circumstances. KEY: 1 = Minimal property change at 200° F (93° C) 2 = Minimal property change at 185° F (85° C) 3 = Minimal property change at 140° F (60° C) 4 = Minimal property change at 70° F (21° C) 5 = Not Recommended

Acids Kerosene ...... 1 Perchloroethylene ...... 1 Acetic Acid, 20% ...... 1 Lubricating Oil ...... 1 Calcium Phosphate ...... 1 Acetic Anhydride...... 1 Mineral Oil ...... 1 Calcium Sulfate ...... 1 Acetic Acid, Glacial...... 1 MotorOil...... 1 Carbon Dioxide ...... 1 Arsenic Acid ...... 1 Naphtha ...... 1 Carbon Disulfide ...... 2 Benzene Sulfonic Acid ...... 1 Naphthalene ...... 1 Copper Chloride ...... 1 Benzoic Acid ...... 1 Stoddard Solvent...... 1 Copper Cyanide...... 1 Butyric Acid ...... 1 Toluene ...... 1 Copper Nitrate ...... 1 Carbonic Acid ...... 1 Xylene ...... 1 Copper Sulfate ...... 1 Citric Acid ...... 1 Nitro Compounds Ferric Chloride ...... 1 Chloroacetic Acid ...... 1 Nitrobenzene ...... 1 Ferric Nitrate ...... 1 Chlorosulfonic Acid ...... 5 Nitromethane ...... 1 Ferric Sulfate ...... 1 Chromic Acid, up to 30% ...... 2 Ferrous Chloride ...... 1 Formic Acid ...... 1 Phenols Ferrous Sulfate ...... 1 Chlorophenol, 5% Aqueous ...... 1 Fluoboric Acid ...... 1 Hydrogen Gas ...... 1 M-Cresol (Crude) ...... 1 Fluosilicic Acid ...... 1 Hydrogen Peroxide, 50% ...... 5 lnorganics Glycolic Acid ...... 1 Hydrogen Sulfide (Wet) ...... 1 Aluminum Chloride (Dry)...... 1 Hydrochloric Acid, 0-37% ...... 3 Lead Acetate ...... 1 Aluminum Sulfate ...... 1 Hydrobromic Acid ...... 3 Magnesium Chloride ...... 1 Flouride ...... 1 Hydrofluoric Acid, 10-50% ...... 3 Magnesium Hydroxide ...... 1 Chlorohydroxide (Wet) ...... 1 Lactic Acid ...... 1 Magnesium Sulfate ...... 1 Ammonium Carbonate ...... 1 Nitric Acid, 10% ...... 3 Nickel Chloride ...... 1 Ammonium Chloride ...... 1 Nitric Acid, Conc ...... 5 Nickel Sulfate ...... 1 Ammonium Nitrate ...... 1 Oleic Acid ...... 1 Nitrogen ...... 1 Ammonium Phosphate ...... 1 Phosphoric Acid, 0-100% ...... 1 Potassium Bromide ...... 1 Ammonium Sulfate ...... 1 Sulfuric Acid, 0-10% ...... 1 Potassium Carbonate ...... 1 Barium Chloride ...... 1 Sulfuric Acid, 10-75% ...... 4 Potassium Chlorate ...... 1 Barium Sulfate ...... 1 Sulfurous Acid ...... 1 Potassium Chloride ...... 1 Borax (Sodium Borate) ...... 1 Tannie Acid ...... 1 Potassium Cyanide ...... 1 Bromine (Wet) ...... 1 Tartaric Acid ...... 1 Potassium Dichromate ...... 1 Cadmium Cyanide ...... 1 Potassium Nitrate ...... 1 Alcohols Calcium Chloride ...... 1 Potassium Permanganate ...... 1 Amyl Alcohi ...... 1 Calcium Hypochlorite ...... 1 Potassium Sulfate ...... 1 Butyl Alcohol ...... 1 Calcium Nitrate ...... 1 Silver Nitrate ...... 1 Cyclohexanol ...... 1 Ethylene Glycol ...... 1 Sodium Acetate ...... 1 Ethyl Alcohol ...... 1 Gl;ycerine ...... 1 Sodium Bicarbonate ...... 1 Methanol ...... 1 Esters Sodium Bisulfate...... 1 Amyl Acetate ...... 1 Propyl Alcohol ...... 1 Sodium Carbonate ...... 1 Butyl Acetate ...... 1 Aldehydes/Ketones Sodium Chlorate...... 1 Butyl Phthalate ...... 4 Acetaldehyde ...... 1 Sodium Chloride ...... 1 Cresyldiphenyl Phosphate ...... 1 k ...... 1 Sodium Chromate ...... 1 Dimethyl Phthalate ...... 4 Benzaldehyde ...... 3 Sodium Cyanide ...... 1 Dioctyl Phthalate ...... 4 Formaldehyde, 37% ...... 1 Sodium Hypochlorite Soln ...... 1 Ethyl Acetate ...... 1 Furfural ...... 1 Sodium Nitrate ...... 1 Ethers Methyl Ethyl Ketone ...... 4 Sodium Sulfate ...... 1 Butyl Ether ...... 1 Methyl Isobutyl Ketone ...... 4 Sodium Silicate ...... 1 Cellosolve ...... 1 Amines Sodium Sulfide ...... 1 Cresyidiphenyl Phosphate ...... 1 Aniline ...... 1 Sodium Thiosulfate ...... 1 P-Dioxane ...... 1 N-Butylamine ...... 4 Stannic Chloride ...... 1 Diphenol Ether ...... 1 Dimethyl Aniline ...... 1 Sulfur Dioxide ...... 1 Furan ...... 1 Ethanolamine ...... 1 Steam 300°F ...... 1 Tetrahydrofuran ...... 1 Ethylene Diamine ...... 5 Trisodium Phosphate ...... 1 Hydrocarbons Triethanolamine ...... 1 Water, Dionized...... 1 Acetylene ...... 1 Bases Sea ...... 1 Benzene ...... 1 Ammonia, Aqueous ...... 4 Tap ...... 1 Butane ...... 1 Ammonium Hydroxide ...... 1 Zinc Chloride ...... 1 Butylene ...... 1 Barium Hydroxide ...... 1 Zinc Sulfate ...... 1 Crude Oil (Sour) ...... 1 Ferric Hydroxide ...... 1 Miscellaneous Cyclohexane ...... 1 Potassium Hydroxide, 50% ...... 1 Asphalt Emulsions ...... 1 Decalin ...... 1 Sodium Hydroxide, 20% ...... 1 Cottonseed Oil ...... 1 Detergents ...... 1 Sodium Hydroxide, 50% ...... 3 Dowtherm ...... 1 Diesel Fuel ...... 1 Chlorinated Organics Freon (Fluorocarbons) ...... 1 Diisobutylene ...... 1 Chloroform ...... 4 Soaps ...... 1 Fuel Oil ...... 1 Carbon Tetrachloride ...... 3 Tomato Juice ...... 1 Gasoline...... 1 Ethylene Dichloride ...... 3 Turpentine (Dry) ...... 1 Heptane ...... 1 Methyl Chloride ...... 4 Urea...... 1 Hexane ...... 1 Methylene Chloride ...... 4 Vegetable Oil ...... 1 JP Fuels ...... 1 Vinegar ...... 1

113

UDEL® POLYSULFONE

Polysulfone is a high performance thermoplastic known for its high temperature resistance, hydrolytic stability and excellent machinability. These characteristics have helped polysulfone replace metals, glass and ceramics in a wide variety of applications. Polysulfone possesses good resistance to a wide variety of aggressive environmental conditions. Polysulfone is also highly resistant to aqueous mineral acids, alkali, and salt solutions. The material's resistance to detergents and hydrocarbon oils is also good, even at elevated temperatures under moderate levels of stress. Polysulfone also exhibits exceptional steam resistance, including exposure to high temperature and pressure conditions. Its resistance to radiation is the highest known among plastics. Polysulfone's long-term resistance to environmental stress cracking has opened up many new application areas where the user can take advantage of the bonuses of economical fabrication and light weight products. These areas include chemical processing equipment, food processing components and piping, gas scrubbing and pollution control devices, filtration equipment, and parts involivng contact with highly caustic environments.

SUPERIOR STIFFNESS AT EFFECTS OF BOLING HIGH TEMPERATURES WATER IMMERSION 20,000 ---'"''""""'"-'"""'""""'""'"--- 16,000 Pclysu!fone

Polycarbonate

0 8 16 24 Days 32 40 48 56

40 50 100 150 200 250 300 350 " -'----'-----'-----'----'----'------' TEMPERATURE, "F 0 8 16

Availability Rod (Diameter) 1/8"-5" (Lengths) 48"-96" Sheet/Slab (Thickness) .020"-4½" (Size) 24" x 48", 48" x 96" Film (Gauge) .005"-.010" Tubing (Custom)- Standard 1/4" x 3/16", 3/4" x 5/8" Custom Profiles Applications Polysulfone has replaced many plastics, upgrading temperature and other performance parameters. It competes extensively with glass and such metals as stainless steel, brass and nickel, bringing to many applications the economies of thermoplastic fabrication as well as light weight. Electrical/Electronic - Printed circuit boards; integrated circuit carriers; TV and stereo components; business machine parts; antenna mounting bases. Medical - Surgical tool trays; humidifiers; instrument housings; dental and surgical instruments; fluid containers; heart valve cases; pacemakers; respirators; lab equipment. Consumer Products - Microwave cookware; specialized cooking appliances; beverage and food dispensers. Automotive/Aerospace - Under-the-hood components; electrical gear; battery caps; aircraft interior and exterior components; astronaut's outer face mask shields; fuse housings. Food/Beverage - F.D.A. approved for contact with foods and beverages. Chemicals - Gaskets, valves, bearings and bushings in corrosive environments.

114

POLYSULFONE UDEL®

TYPICAL PHYSICAL PROPERTIES ASTM TYPICAL VALUES GENERAL Melt Flow, @650°F (343.3°C), 44psi (0.30 MPa), g/10 minutes D-1238 Density, Mg/m 3 D-1505 124 Mold Shrinkage, in.fin. or mm/mm D-955 0.007 Water Absorption, % in 24 hours D-570 0.3 MECHANICAL Tensile Strength at Yield, psi (MPa) D-638 10,200 (70.3) Tensile Modulus, psi (MPa) D-638 360,000 (2,482) Tensile Elongation at Break, % D-638 50-100 Flexural Strength, psi (MPa) D-790 15,400 (106.2) Flexural Modulus, psi (MPa) D-790 390,000 (2,689) lzod Impact, @72°F (22°C), 1/8" (3.2mm)

Specimen, ft.lb.fin. notch (J/m) D-256 1.3 (69)

lzod Impact, @-40°F (-40°C), 1/8" (3.2mm) Specimen, ft.lb.fin. notch (J/m) 2 Tensile Impact, ft.lb./in.2 (kJ/m ) D-1822 200 (421)

Rockwell Hardness D-785 M69 (R120)

THERMAL Heat Deflection Temp. @264 psi (1.8 (MPa),

OF (C) D-648 345 (174) Coefficient of Linear Thermal Expansion, 0 5 5 in.fin./-° F (mm/mm- C) D-696 3.1x10 (5.6x10 ) Flammability* Average Time of Burning (ATB), seconds D-635 5 Average Extent of Burning (AEB), in. (mm) D-635 0.058 in. (1.47 mm) UL (File No. 0.120 in. (3.05 mm) E-36098A) 0.240 in. (6.10 mm) Oxygen Index Rating D-2863 T 30 Thermal Conductivity, btu-in./ft. 2 hr.-°F (YV/m-° C) C-177 1.8 (0.26) ELECTRICAL Dielectric Strength, 130 mils, Specimen, SIT, v/mil D-149 425 Arc Resistance, sec. (Tungsten Electrodes) D-495 122 16 Volume Resistivity @ 72°F (22°C), ohm-cm D-257 5 X 10 Dielectric Constant@ 72°F (22°C) 60 Hz-1 MHz D-150 3.07 - 3.03 Dissipation Factor @ 72°F (22°C) 60 Hz-1 MHz D-150 0.0008-0.0034 *Note: This numerical flame spread rating is not intended to reflect hazards presented by this or any other materials under actual fire conditions.

115

CHEMICAL RESISTANCE DATA

"-§", .=,, ,E i al = =t:;l a i 8 .,,= · '§:: j t is: is: © = :i; ,E l -© g = § o= !le. fl = g 1 ,=:- ,=:- " 8 =< :; 5 5 i u:: - .!2 "'"" ii ! Acetaldehyde Aq. 40 A ACltamide Aq. 50 Acetic Acid Aq. 10 A A Acetone A A A Acrylonitrite A Alcohols, Aliphatic

Allyl Chloride Allyl Alcohol A A A Aluminum ChlorideAq. 10 A A A Aluminum Sulphate Aq. 10 A A A A Ammonia Aq. 10 A A 0 A A

Ammonia Gas A A A A A Ammonium Carbonate Aq. 10 A A A A A A A Ammonium Chloride Aq. 10 A A A A A 37 A A Amyl Acetate 0 A 0 0 Amyl Alcohol A A A A A A

Aniline A A A A Antimony Trichloride Aq. 10 A A A A A A Barium Chloride Aq. 10 A A A A A Barium Sulphate Aq. 10 A A A A A A A Barium Sulphide Aq. 10 A A A A A A Benzaldehyde 10 A A B Benzene A Benzene Sulphonic Acid 10 A A Benzyl Alcohol A A A Benzoic Acid Aq. SAT A A A Beverages Aq. Alcoholic A A A A

Carbonated A C A Bitumen A A Bleaching Lye 10 A A A A A 100 A A Boric Acid Aq. 10 A A A Boron Trifluoride A A

BromineAq. 30 A A Bromine liq. 0 Butanol A A Butyl Acetate Butyl Phthalate A A Butylene Glycol A A A Butylamine Butyric Acid Aq. 20 A Butyric Acid C0HC A B Butyrolactone A A Calcium Chloride Aq. 10 A A A A Calcium Chloride !in Alcohol) 20 A A A A Calcium Hypochlorite A A A A A Camphor A A Carbon Disulphide A A Carbon Tetrachloride A A A A A Carbonic Acid Aq. 10 A A A A A

Carnallite Aq. 10 A Catechol C Chloracetic Acid Aq. 10 A Chloral Hydrate A A Chlorine Aq. 10 A Chlorine Gas 100 A Chlorobenzene A Chloroform A Chlorosulphonic Acid Aq. 10 A Chrome Alum Aq. 10 A A Chromic Acid Aq. 10 A A A - No attack, possibly slight absorption. Negligible effect on mechanical properties. B - Slight attack by absorption. Negligible effect on mechanical properties. C - Moderate attack or appreciable absorption. Material will have limited life. D - Material will decompose or dissolve in a short time. - - No data available.

117

CHEMICAL RESISTANCE DATA

-,. = =t:i al I -:;:; :a ""= - k ,E -i5, . ! $2 ,a § g "5- ,;;, ,c- 0.- 0.- [ · "' iil = 1 t 1 -© 0 ,a ,E 8 = < < 9 = § ,so:!5 - ,so- "' ll Citric Acid Aq. 10 A A "'"" SAT A A Castor Oil A A A A A A A Coconut Oil B B A A A Creoso1e A Cresols

Cresylic Acid A A Cupric Chloride Aq 10 Cupric Sulphate Aq. 0.5 A 10 SAT A Cyclohexane A Cyclohexanol A A B Cyclohexanone A A A Decalin Detergents, Organic Oibutylphthalate Oichlorodigluoro Methane A Dichloroethylene Oiethyleneglycol Aq. 00 A A A Diesel Oil A A Oimethyl Carbinol A Dimethyl Aniline A

Dimethyl Formamide A Dictyl Phthalate A Oioxan A A A Edible Oils A A A Ethanol Aq. 96 A Ether, Diethyl A Ethyl Acetate A A A Ethyl Butyrate A A Ethyl Chloride Ethylene Chlorhydrin A Ethylene Chloride A

Ethylene Diamine A Ethylene Oichloride A Ethylene Glycol Aq. 96 A A A A Ethylene Propionate A A Ferrous ChlorideAq. A 19 A

SAT A Ferrous Chloride Aq. 10 A A A Fluorine A Fluosilicic Acid Aq. 10 A Fluothane A

Freon 12 IArcton 12) A A A A formaldehyde Aq. 40 A A B A formic Acid Aq. A A 10 A A fruit Juices CONC A A A furfural C D A

Glycerine A A A A A A Heptane A A A A A A Hexane A A A A A A Hydrobromic Acid Aq. 10 D A A D Hydrochloric Acid Aq. 0.4 A A A A A A A 10 A A A A A Hydrofluoric Acid Aq. A A A Hydrogenated Vegetable Oils A Hydrogen Peroxide Aq. 0.5 A

A - No attack, possibly slight absorption. Negligible effect on mechanical properties. B - Slight attack by absorption. Negligible effect on mechanical properties. C - Moderate attack or appreciable absorption. Material will have limited life. D - Material will decompose or dissolve in a short time. - - No data available.

118

CHEMICAL RESISTANCE DATA

= t :!! i " " .la a ii: - = i--a; 2!l8 -[ e -·;,; ii: -,:; .la >- "a!: I t § \ \Is -"' ll! iii = = i!l. § =Q - 8 .1'l 5 £ = "' - $ ,2C' "'"" !l ,;;;- Hydrogen Peroxide Aq. A A A A A A A Hydrogen Sulphfide Aq SAT A A A A A A A A Hydroquinone A A B Iodine lin Alcohol! A A Iodine lin Pot. Iodine! Aq. A A

lsooctane A A A

lsopropylalcohol A B A lsopropyl Ether A lactic Acid Aq. 10 A A A A A A 00

Lead Acetate Aq. 10 A A A A A A

lead Stearate A A Linseed Oil A A A A A A A A A Lubricating Oils !Petroleum! A A A lithium BromideAq. 50 A A A Magnesium Chloride Aq. 10 A A A A A A A Magnesium Hydroxide Aq. 10 A Magnesium Sulphate Aq. 10 A A A Maleics Acid CONC A A Malonic Acid Aq. CONC A A Manganese Sulphate Aq. 10 A A A Mercuric Chloride Aq. A A A A A A C Mercury A A Methanol A A Methyl Acetate A Methyl Ethyl Ketone A A A Methyl Pyrrolidone A Methyl Chloride C Methyl Phenyl Ether A Milk A A A A Mineral Oils C A A Naphthalene A B A A 0 A C Nickel Sulphate Aq. 10 A A A A A A A A A Nitric Acid Aq. 0.1 A A A A A A 10 A Nitrobenzene Nitromethane B Oleic Acid A A A A A Oleum 0 Oxalic Acid Aq. 10 A A A A Ozone C A A Paraffin A Perchlorethylene A A Perchloric Acid Aq. 10 A A A Petrol A A A Petroleum Ether A A A A Phenol Aq. A 75 Phenol !Molten! A C A Phosphoric Acid Aq. 0.3 A A A A A A A A. A A A A A 10 A A A A Phthalic Acid Aq. SAT A Potassium Acetate Aq. 50 A A A Potassium Bicarb. Aq. 60 A A A A A A Potassium Bromide Aq. 10 A A A A A A Potassium Carbonate Aq. 60 A A A A A A Potassium Chloride Aq. 00 A A A A A A A Potassium Dichromate Aq. A A Potassium Ferricyanide Aq. 300 A A A A A Potassium Ferrocyanide Aq. 30 A

A - No attack, possibly slight absorption. Negligible effect on mechanical properties. 8 - Slight attack by absorption. Negligible effect on mechanical properties. C - Moderate attack or appreciable absorption. Material will have limited life. D - Material will decompose or dissolve in a short time. - - No data available.

119

CHEMICAL RESISTANCE DATA

[ "=' i i i .= I .E:!! 0 a "' ;Jij 8 ·; it ..= .E l/;: it =-©= i igp ; .. >- ·§ 8 "' .\, 9 [ u: 1,'i! = Q= ,i;;' J ; :;; = Potassium Hydroxide Aq. 10 C A A A A ""°" A A - 50 }! A

Potassium Nitrate Aq. 10 B A

Potassium Permanganate Aq. A A A Potassium Sulphate Aq. CONC A A A A Potassium Sulphide Aq. 00 A A A A A Pyridine A A

Propane Gas A A A A

Resorcinol A C Salicylic Acid A Silicone Fluids A A A Silver Nitrate A A A Soap Solutions A A

Sodium !Molten)

Sodium Acetate Aq. 60 A A A A A Sodium Benzoate Aq. 10 A A A A A A Sodium Bicarbonate Aq. 50 A A B A A A - Sodium Bisulphite Aq. 10 A A A A Sodium Bromide Aq. 10 A A A

Sodium Carbonate Aq. 20 A A A A A

50 A A A Sodium ChlorateAq. 10 A A A Sodium Chloride Aq. 10 A A A 00

Sodium Cyanide Aq. 10 A A A A

Sodium Hydroxide Aq. 10 A A A A A A A A A A 50 A A A A A A Sodium Hypochlorite 15% Cl A A A D B A Sodium Nitrate Aq. 50 A A A A A Sodium Perborate Aq. 10 A

Sodium Phosphate Aq. 00 A A A A A

Sodium Silicate A A A A A A A Sodium Sulphate Aq. 00 A A A A Sodium Sulphide Aq. 00 A A Sodium Thiosulpha1e Aq. 10 A A A A A

Stannic Chloride Aq. 10 A A A

10 A Stannic Sulphate Aq. A Stearic Acid A Styrene !Monomer) A A A Sulphur A A A A A A Sulphur Dioxide !Ory Gas) 100 A A A A A A A

Sulphuric Acid Aq. A A A A A A A

A A A A Sulphurous Acid Aq. 10 A A Tallow A A A Tar A A Tartaric Acid Aq. 10 A A A A A

Tetrachlorethylene A A

Tetrahydrofuran A A A Tetralin A Thionyl Chloride A A Thiophene A A Toluene A A

Transformer Oil A

Trichlorethylene A Triethanolamine A Turpentine D A A A Trisodium Phosphate Aq. 95 A A A A A

Urea A A A A A A A

Vaseline A A A A A A A A A Vegetable Oils A A A A Vinegar B A A A A A A - No attack, possibly slight absorption. Negligible effec1 on mechanical properties. B - Slight attack by absorption. Negligible effect on mechanical properties. C - Modera1e attack or appreciable absorption. Material will have limited life. D - Material will decompose or dissolve in a short time. - - No data available.

120

CHEMICAL RESISTANCE DATA

,P ..,= .e 0 I ::= "' = ]1 is': is': -"®""' i 1 ·t \g j I :re !o: gj =!:<. i ® g '=-"' = .g g ,c.,.=., · : !l. = = :;; : ! l . ,a:- j5 i l , a : - 8 u:: Vinyl Chloride 5 = A Water A -A A A Wax (Molten) A A A A White Spirit A A A A Wines and Spirits A A A A B Xylene A A A 0 A Xylenol A A Zinc Chloride AQ. 10 A A A A A Zinc Oxide A A A A Zinc Sulphate AQ. 10 A A A A A A - No attack, possibly slight absorption. Negligible etfec on mechanical properties. B - Slight attack by absorption. Negligible effect on mechanical properties. C - Moderate attack or appreciable absorption. Material will have limited life. D - Material will decompose or dissolve in a short time. - - No data available.

Where aqueous solutions are shown, the concentration as a weight percentage is given.

AQ. = Aqueous Solution SAT= Saturated Aqueous Solution CONG = Concentrated Aqueous Solution

This information, based on our experience, is in line with accepted engineering practice and is believed to be reliable. However, we do not warrant the conformity of our materials to the listed properties or the suitability of our materials for a particular purpose. This publication is not to be taken as a license to operate under, or a recommendation to infringe, any existing patents.

121

COMPARATIVE MATERIAL PRICE POSITION ONE INCH DIAMETER ROD ASSUMING 1 11 0 PVC ROD COST 1.0

PVC ...... 1.0 Delrin® 500CL ...... 5.5

UHMW ...... 1.1 Delrin® AF ...... 8.6

Polypropylene ...... 1.2 Ultem® ...... 8.9

Nylon ...... 1.7 Hydlar® ZM MOS2 ...... 9.2

Nylatron® ...... 2 Teflon ...... 9.3

Acetron® ...... 2.1 Grade C Phenolic ...... 1O

DeI.r.In® ...... 2 .1 Grade L Phenolic ...... 10.8

ABS ...... 2.2 Polysulfone ...... 11.6

Acrylic ...... 2.4 Fluorosint® 500 ...... 17.4

PET ...... 2.5 Kynar® ...... 17.9

Styrene ...... 2.6 Rulon® ...... 32

CPVC ...... 3.2 Techtron® ...... 35

Polycarbonate ...... 3.2 PEEK ...... 45

Nylon ST 801 ...... 4.2 Torion® 4301 ...... 56.3

Noryl® (PP) ...... 4.9 Kel F® ...... 63

Hytrel® ...... 5.5 Vespel® SPI ...... 275

122

PLASTICS BEARING DESIGN

Evaluating bearing properties requires knowledge of the for the cycle time, if continuous operation is not required. most critical operating conditions under which your bearing Modification of PVais accomplished by multiplying by will perform. You should select the appropriate themoplastic factors (T & C) obtained from Graphs 1 and 2 which are with a knowledge of the following factors: PV, Operating PV, located on page 124. Ambient Temperature Correction and Cycle Time If continuous oil lubrication is supplied to the bearing, the Correction. PV capabilities are greatly increased and are more dependent on the type and volume of lubricant. In such PVVALUE cases, nylon bearings can perform as well or better than Frictional Heat Build-Up bronze bearings if the unit load does not exceed 2,000 psi, Although plastic bearings tend to entrap generated the ambient temperature does not exceed 100°F., and the frictional heat, much of this heat may be conducted away running clearances are increased to conform to this manual. through a metallic shaft. The surface temperature of a For intermittent sliding, oscillating, and reciprocating bearing in operation depends upon heat generation rate motion, unit loads as high as 4,000 psi are permissible. resulting from friction, and upon heat dissipating characteristics of the bearing, shaft, lubricant, and housing. AMBIENT TEMPERATURE CORRECTION Two factors affecting the heat generation rate which can Ambient Temperature Correction-T be readily determined include the unit pressure (P), When the ambient temperature (surrounding temperature, expressed as pounds per square inch or PSI, and surface not heat generated in the bearing from operation) is higher velocity M, expressed in feet per minute. Multiplying P or lower than 75°F., the PV capabilities change. times V to obtain PV reliably reflects the heat generation Heat generally softens plastics and reduces their load rate of bearings. PV is an expression of the combined carrying capabilities. An increase in ambient temperature effects of pressure from the shaft on the bearing surface reduces temperature rise before failure of the bearing and the surface speed of the shaft which together create material. Graph 1 illustrates the relation of ambient heat through friction. Increase the unit pressure on the temperature to necessary modification of PVa. bearing surface and more frictional heat will develop; CYCLE TIME CORRECTION increase the shaft speed and this will also create more Cycle Time Correction-C frictional heat. Since the rates of heat generation and dissipation greatly If a plastic bearing should fail, it is usually due to melting determine the performance of plastic bearings, it can be caused by frictional heat being generated more rapidly than understood that if operation is intermittent rather than it can be dissipated from the bearing. In other words, the PV continuous, the rate of heat generation is reduced although imposed on the bearing is greater than the PV capability of the rate of heat dissipation remains constant. Therefore, if a the bearing. Through experience, maximum recommended plastic bearing has a short on period compared to a PV's have been determined for bearing materials. These relatively long off period, the applied PV during the on values can be found on Table 1 below. period can be increased as the generated heat dissipates To determine if a plastic bearing should be considered in during the off period. Graph 2 illustrates the relation of cycle an application, it is only necessary to compare the imposed time to the allowable modification of PVa. PV expected to the PV rating of the bearing material after Note: When ambient temperature is 75°F., or normal room corrections are made for ambient operating temperature temperatures, T=1.0. When bearings are run continuously, and cycle times. C=1.0. If, for example, as is often the case, a bearing is to MEASURING OPERATING PV be run at room temperature and continuously, T=1.0 and Determining Surface Velocity C=1.0 and, therefore, PV would equal the value of PVa and For sleeve bearings, the formula V =.262 x rpm x D is can be taken directly from Table 1. used to determine the surface velocity in fpm, from the shaft diameter, D (in.) and the shaft revolutions per minute, or Table 1: Basic Limiting PV (PVa) for Bearing Materials rpm. For linear motion, the surface velocity is the speed at operating without lubrication and with ambient temperature which the sliding surface is moving across the mating of 75°F. Units of PVa are (PSI} (FPM). surface. Determining Unit Pressure The unit pressure P is quickly calculated for flat wear surfaces and sleeve bearings. For flat bearing surfaces, unit PVa pressure P is simply the total load (lbs.) divided by the total Material Unlubricated contact area expressed in square inches (in.21. For sleeve Nylatron® NSM 15,000* bearings, the unit pressure P is calculated by dividing the Torlon®4301 11,250** total load on the bearings by the projected area of the Nylatron® NS 10,000* bearing surface. The projected area of sleeve bearings is Acetron®NS 8,750 calculated by multiplying the bearing I.D. (inches) by the Fluorosint® 207, 500 8,000 bearing length (inches). MC® 901/Nylatron® GSM 3,000 Since the unit pressure P and the surface velocity V have Nylatron® GS 3,000 been determined in the preceding examples, PV (which is P Nylon 101/Acetal 2,700 x V) can now be obtained.

Applying the PV Factor *At surface speeds below 20 ft. I min. the PVa (Basic Table 1 presents PVa values for various Polymer plastic Limiting PV) may be doubled. bearing materials. PVa is the maximum PV that a given **Value represents the PVa for a machined part without post material can withstand at 75°F., running continuously with curing after machining. Post curing parts machined from particular conditions of lubrication. The basic PVa taken Tor/on 4301 increases the PVa to as high as 75,000. from this table must be modified when necessary to compensate for ambient temperatures other than 75°F. and

123

Graph 1 Graph 2 Ambient Temperature Correction 'T' vs. Cycle Time Correction "C" vs. Operating Period Ambient Temperature 10 4X 1.5 (.) c..:, 9 'r-..

I I I 2 1.4 I\ I " - - - MC NYLONVNYLATRON GSM/NSM 0 i"- \ j:: 8 - • - NYLATRON GS, NYLATRON NS c..:, 1.-3 - • - NYLON 101/ACETAUACETRON NS LU 3X cc -i--. r--,.0\ ------FLUOROSINT 500 & 207, TORLON 4301 cc 7 1'. 0 r--.. 1.2 c..:, f\. LU 6 I""-. " z ,\- 0 >c..:, c..,j::1.1 cc 5 2X I'--- t{, -i---... LU LU 0: 1.0 en ...... 0: f - I'-.. 0 1 z 4 r--... " c.., .9 LU

LU !\\ I= 1)(_ 'I'-.. ::::, cc f'..,_ I- r- LU "' <( "I'---. ' f- t--r---- r--... ,_ 0: .7 L' ' 2 -- 0 LU ' --i-... 0.. \ t--.r ------: l \\ ' I'--- 2 .6 ' i--.. i::::-- i:--.. LU "\\ I- \ ' I - \ ' ' z 0 LU .5 \ ' 1 2 3 4 6 8 10 20 30 50 1 2 3 4 5 6 7 8 9 iii ' \. ' ' ' 2 <( .4 1q_ ' r- ,_ SECONDS -----I--- MINUTES \.. \\ ' ' OPERATING PERIOD .3 ' ' )-, ' ' .2 ' " '- ' Instructions for Use of Graph 2

.1 Locate operating period or on period on horizontal scale. Read .0 upwards to intersect with the appropriate curve. If the off

0 100 200 300 400 500 period is the same as the on period, use the (1X) curve. If the AMBIENT TEMPERATURE (°F) oft period is two times the on period, use the (2X) curve. Interpolate conservatively. For example, if off period is three and one-half times the on period, use the (3X) curve.

Graph 4 Graph 3 Shaft Allowance, (a1) Versus Shaft Diameter Recommended Wall Thickness Versus 1 mi.= .001· 1.0 Shaft Diameter /

.9 .- 30 ,, ,.; ' .8 -- 1,, I c\ _,,.- .7 I/ '\O ' h .6 . c\"'t; 11 "--' .5 '1,\}'0 ·•-•"'- I/ 25 10.e i l;..ne., - .-- 11oell , .4 17 I-';"' I ·.t.-- t-- . II\ \',eco!l\11\e .3 J ,, I, V •- . 11ea1lfia"1;'!1\ll .2 o e1a\lll'!_.- 1ess111e ...... _,,, .1 I/ '!ieatill

7

I

10 I

I

I '

0 0 2 3 4 5 6 7 8 9 10 11 12 13 Shaft Diameter (inches)

124

PLASTIC BEARING DESIGN

Nominal Wall Thickness The basic shaft allowance (a1) is the same for all plastic bearing In many bearing applications, the nominal wall thickness is materials and depends only on the diameter of the shaft to be dictated by the geometry of existing equipment. The plastic bearing supported. Graph 4 was developed from application data on plastic is designed from the dimensions of the shaft and the housing. bearings. When new equipment is being designed, the engineer is at greater Wall thickness allowance (a2) is derived from the coefficients of liberty establishing nominal wall thickness. Graph 3 on page 111 thermal expansion for the plastic bearing materials. Each plastic suggests a range of nominal wall thicknesses for different shaft reacts to changing temperatures at a characteristic rate. The thicker diameters. Maximum walls are recommended for bearings the bearing wall, the more material there is available to expand with subjected to severe impact conditions, minimum walls for bearings higher temperature. Hence, Table 2 demonstrates that with higher operating near the material's maximum recommended PV. ambient temperatures and/or thicker bearing walls the greater the Note: Nominal wall thickness is the difference between the shaft required running clearance. diameter (nominal I.D. of the bearing) and the housing I.D. (nominal If a bearing is to be water lubricated and made from a nylon O.D. of the bearing) divided by 2. Running clearances, press fit material (such as Nylatron® or Monocast® 901), an additional allowance, and tolerances are applied to the nominal O.D., I.D., and clearance must be added for moisture expansion of the nylon. Use wall of the bearing to obtain the design dimensions. clearances below regardless of bearing diameters. Note that as wall Bearing Shape thickness increases, moisture clearance increases in progressively Bearing length to shaft diameter ratio has a noticeable effect on smaller amounts. This is due to the increasing resistance of the the coefficient of friction. For a ratio of about one, that is a bearing thicker sections to moisture penetration. length equal to the shaft diameter, the coefficient of friction is MOISTURE EXPANSION CLEARANCE (only if water•lubricated nylon bearing) generally lowest. As the bearing length is increased to two or three If bearing wall thickness 1/8 3/16 1/4 3/8 1/2 3/4 1 or more times the shaft diameter, there is an increased probability of local in inches is: heating due to out-of-roundness and slight shaft vibration. On the Clearance in inches is: .012 .017 .021 .026 .030 .032 .033 other hand, very short bearings are often difficult to retain within the Press Fit into Metallic Housing bearing housing. When plastic bearings are press fit into metallic housings or Wear Rate retainers, a recommended interference (Graph 5) should be used to Under unlubricated conditions, when plastic bearings are ensure the bushing is adequately secured to resist rotating with the operating at or near the maximum allowable PV - with specific shaft. During press fitting the resilient plastic bearings must conform conditions of ambient temperature and cycling - an estimated wear to the housing I.D. and, therefore, the I.D. of the bearing rate of 20-40 mils/1000 hours (wear rate for acetal approx. 80 to experiences close-in. It is convenient that the I.D. close-in is 160) of actual running contact can occur. If the imposed PV is approximately equal to the press fit interference. The close-in is considerable less than the maximum allowable PV, a proportional compensated with an additional clearance which is equal to the decrease n wear rate can be anticipated. Rates should be interference. considered very broad estimates as only actual in use testing will Graphs confirm life of bearings. Recommended Press Fit Interference {a:J It is difficult to estimate wear rates for lubricated bearings as this Versus Housing Inside Diameter 34 I I I I depends on the lubricant and the efficiency of its application to the 33 32 - - • -NYLON 101/ACETAUACETRON NS bearing surface. 31 - - MC, GS, GSM, NS, NSM - - Machining Tolerances 30 ------FLUOROSINT 500 and 207, - 29 - When applying machining tolerances to final design dimensions, it - TORLON 4301 -- - 28 is advisable to specify the I.D. as -.000" plus best commercial, and 27 - - 26 the O.D. as +/- best commercial. This practice assures a minimum 25 E 24 running clearance and may provide additional clearance which may be beneficial to the performance of the bearing. j 21; ./ Clearance u ff cc" 2 / ,_ Clearance has been the least understood and most frequently 1 ~ encountered problem in the design of plastic bearings. Almost half "t: 18 / / 17 ,..,, of plastic bearing failures are caused by insufficient clearance. i 16 ,, Plastic bearing clearances are much greater than those u:: 15 , r 14 "' recommended for bronze bearings. Bronze bearings installed with e 13 .,., 0.. 12 / excessive clearance often result in shaft vibrations and a brinnelling 11 / or scoring of the bearing and shaft. Plastics, on the other hand, are 10 , - 9 - far more resilient, resist brinnelling and dampen shaft vibration. 8 ,./ - Total running clearance is obtained by adding three contributions 7 / i/ 6 / or allowances. The total running clearance is then added to the 5 r\ nominal bearing I.D. (shaft diameter) to obtain the actual or design I

/ 1.D. of the bearing. Total running clearance =a1 + a2 + a3 , where: ·, a1 = basic shaft allowance. Obtain value from Graph 4 on page 87. a2 = wall thickness allowance (a function of the bearing material, 0 1 3 4 5 6 7 8 9 ,o 11 12 bearing wall-thickness, and the ambient operating temperature). Houslng ID (inches) l mi!= .001" Obtain wall factor from Table 2 and multiply by the nominal wall Shafts and Mating Parts thickness to obtain a2. Shafts and mating parts perform best if made from hardened and 3 a3 = used only when the bearing is to be press fit. Note that a is ground steel, while unhardened steel surfaces will wear quickly in the same as the recommended press fit interference. Obtain from many applications, particularly if unlubricated. Commercial shafting Graph 5 on page 113. normally is supplied with a surface hardness of Rockwell C-55,

although shafting with Rockwell hardnesses as low as C-35 will Wall Factor for Plastic Bearing Materials at Various Ambient Temperatures For Calculation of (a2) perform satisfactorily. Shafts and mating parts of stainless steel 75 100 125 150 175 200 225 250 275 300 350 400 450 500 should be specified in a hardenable grade. NYLON 101/ACETAU ACETRON NS 18 21 23 26 28 31 33 36 38 Mating metal parts should have a smooth surface like that MC NYLON. GSM, NSM 15 16 18 19 21 23 24 26 26 obtained by grinding or hard plating. Commercial shafting normally NYLATRON GS, NS 13 15 16 18 20 22 23 25 27 is finished to 16 RMS although a 32 RMS or coarser finish will work FLUOROSINT 500 and 207 7 7 8 8 9 9 10 10 11 11 12 13 14 15 in many applications. The finish of the plastic bearing is not critical TORLON4301 7 7 8 8 9 9 10 10 11 11 12 13 14 NOTE: For temperatures other than those given use the next highest temperature which appears in the and can be as coarse as 125 RMS. table.

125

PLASTIC BEARING DESIGN (EXAMPLE)

Examples: Running clearance for GS:

1. A nylon bearing is to be evaluated in a piece of textile a1 = .0045, Graph 4 equipment to replace a bronze bearing in order to eliminate lubrication. The bearing will carry a shaft .500" diameter and a2 = .0033, Table 2 (nominal wall = .250" Wall factor= 13) will be press fit into a 1.000" diameter housing. Bearing a3 = .0045, Graph 5 (This is also press fit) (c) .0123 = .012 length will be .375". total running clearance (b) Ambient temperature of approximately 70-75°F. is The dimension that the I.D. of the bushing should be anticipated. Shaft speed is 400 rpm and an on cycle of 50 machined to is the nominal I.D. (shaft diameter) plus total seconds versus an off cycle of 170 seconds will be normal running clearance. operating conditions. Nominal I.D. plus total running clearance = Determine: Maximum allowable total shaft load for (a) nylon .500" + .012" = .512" 101 and Nylatron GS, (b) running clearance for Nylatron GS and (c) press fit interference for Nylatron GS. The dimension that the O.D. of the bushing should be machined to is the nominal O.D. (housing I.D.) plus press fit V=.262 x rpm x 0= interference (same as a3). .262 X 400 X .500" = 52.4 fpm Nominal O.D. (housing I.D.) plus press fit interference= Maximum allowable PVa from table 1 for Nylon 101 is 2,700. 1.000" + .0045" = 1.005" For GS is 3,000. Ambient temperature correction is 1.0 for both materials since temperature is 75°F. Intermittent service 2. Determine the required length of a non-lubricated correction is ~ 2.6 (Graphs 1 and 2). Fluorosint®500 bearing which must operate continuously at 300°F at 40 rpm. The bearing will be press fit into a housing PV= PVaxTx C 4" in diameter and the shaft will be 3" diameter. Total load For 101: PV = 2,700 x 1 x 2.6 = 7,020 on the bearing is 120 lbs. (maximum allowable) V = .262 x rpm x D = .263 x 40 x 3 = 31.4 fpm For GS: PV = 3,000 x 1 x 2.6 = 7,800 PVa for unlubricated Fluorosint 500 bearings = 2,000 (maximum allowable) (Table 1) P (maximum allowable unit pressure = PV= Ambient temperature correction Tis. 4. (Graph 1) V Cycle time correction C = 1.0 since operation is continuous. 7020 (Graph 2) Maximum allowable 52.4 :::134 psi for 101; and PV = PVa x Tx C = 2,000 x .4 x 1 =800

7800 Maximum allowable P = PV = 800 = 25.5 psi 52.4 :::149 for GS. V 31.4fpm 120 lbs. (total load) Projected area of bearing= length x inside diameter= .375" 25.5 psi (max. allowable P) = 4.74 2 in. X .500" = .1875 in.2 (of projected area is required) For 101: Length (min.)= 4.74 in.• (required area) 3" diameter Shaft load = 134 psi x .1875"2 = 25.12 lbs. (a) = 1.58 inches For GS: Shaft load= 149 psi x .1875"2 = 27.93 lbs. (a)

126

TYPICAL BEARING AND WEAR MATERIALS

THE NS Series Torian* 4301 The NS Series offers the most wear-resistant engineering Poly(amide-imide) withstands temperatures to 475° and is thermoplastics available today. These internally lubricated used where high strength in addition to wear resistance is materials extend the life of wear parts by up to 500%. The required. Exhibits little or no slip-stick in bearing enhanced products of the NS Series give high PV applications. capabilities, low coefficient of friction, and excellent wear characteristics. Nylon 101 Unmodified type 6/6 nylon. Good for general wear Nylatron® NSM surfaces. Cast Type 6 nylon based on the Monocast® process, developed Nylatron® GS for demanding wear applications where parts of a larger size are required. The Monocast process permits the production Molybdenum disulfide filled type 6/6 nylon. Resists of massive shapes not possible by extrusion. deformation under load, and can frequently outperform unfilled 6/6 nylons, enduring temperatures up to 50° F Nylatron® NS higher. Extruded Nylatron® GSM Type 6/6 nylon recommended for dry service applications and where, in addition to superior bearing performance, Cast type 6 nylon with molybdenum disulfide added. other traditional 6/6 nylon properties such as resilience, and Monocast process permits the production of massive impact resistance are desired. Nylatron NS is available in rod shapes in GSM. up to 2" diameter. Acetal Acetron® NS Extruded acetal copolymer or homopolymer offering low Extruded moisture absorption. Recommended for dry or wet service Acetal-based material ideally suited for wet service applications. Excellent machining characteristics. applications due to its superior dimensional stability and low MC®901 moisture absorption. Additives provide lubrication during break-in and contributes to the superior wear resistance of Cast heat stabilized type 6 nylon available in massive the material. It is easy to machine, and is recommended for shapes. Blue in color. Can be used in applications up to close tolerance parts. 250°F. Fluorosint® 500 MC® 907 Natural Synthetic mica-filled PTFE with exceptional load bearing Cast unfilled type 6 nylon available in massive shapes and capabilities and heat resistance to 500°F. Good electrical offering FDA and USDA compliance. properties and outstanding chemical resistance. Fluorosint® 207 Synthetic mica-filled PTFE with lower fill level than Fluorosint 500 resulting in a more ductile material. FDA and USDA compliant.

127

DESIGN WORKSHEET - PLASTIC BEARINGS

Information Required:

Housing Bore in. Shaft Diameter in. Length 1n.

Shaft rpm _ Bearing Load ------bs. How many bearings/shaft, _

Ambient Temp. °F Cycle-Continuous _ Intermittent _ time on _ time off _

Is Bearing Lubricated? _ How?

PV DETERMINATION:

Projected Area = ID xLength Sq. In.

• Pressure = Bearing Load +Projected Area '!!------=. I_ .psiI

• Velocity = .262 x rp x shaft diameter _ =I, f .pml ( (■) do not exceed 400 fpm) * PV =• p x ■ ------m=LI P_V or imposed PV on Bearing

* See Table 1 page 5 for Limiting ♦ PV - Lubricated Unlubricated _

Material Selected _

Corrections for Limiting PV - See pages 6 and 7 for Graph 1 and Graph 2

Graph #1-Temperature Correction T=I :·======Graph #2 - Cycle Time Correction C =. I , PV CORRECTION = * Limiting PV ♦- - - - · Tem p. (T) x Cycle (C) _ = LI P_V_L_im_it_,I

* If imposed PV is less than the PV limit for the material selected the bearing will work.

128

DESIGN WORKSHEET - PLASTIC BEARINGS

Total Running Clearance - Page 6 = a1 + a2 + as

a1 = Graph 4, page 10

a2 = Table 2, page 10 for ambient temp. to 90°F

Bearing wall= ( O=D_---=-=ID""--_ ) x Temperature (K) factor for material x .001" 2 wall x K x .001

as = Graph 5, page 11 - used if bearing is press fit =------

Dimension Bearing A. OD of bearing= Housing Dia. + as _

B. ID of bearing= Shaft Dia. + a1 _ •= --- *

If a nylon bearing is to be used in a water lubricated environment, add factor given on page 11 to the ID of the bearing to allow for moisture absorption. (Acetals are preferred in wet environments).

*Fill in only if water lubricated + • _ Table "D" C. Length of Housing *----

Dimension + Tolerance

+ OD= V _ + .004 or + .001 inch/inch of dia. OD=

+ .008 + - .000 or+ .002 - .000 inches/inch of dia. ID= - .000"

+ Length =* _ + .010 or :!:_ .001 inches/inch oflength Length=

The greater of the tolerances will apply. This sheet applies to sleeve bearings - if the bearing has another configuration, sketch and note all dimensions.

129

PLASTICS GEAR DESIGN

Introduction Advantages Nylatron® nylon gears have been used in tough industrial Nylatron® nylon gears are produced under the strictest applications for many years. However, as a result of the quality control, by exclusive processes, and offer these Federal Coal Mine Health and Safety Act in 1969, the important advantages: Occupational Safety and Health Act of 1970 and the 1972 Noise Reduction Noise Control Act, the sound damping characteristic of Nylatron nylon has received increased importance in gear The resilient nature of Nylatron nylon gears allows them to design. We have some examples where the mere change run quietly, and absorb much of the noise generated by from a metal gear to a Nylatron gear has reduced the dBA mating parts. Nylatron gearing has substantially reduced level from above the current legal specified limit to noise levels in gear trains on equipment such as pulp and significantly below. In addition to the sound reduction paper making machines, textile machinery, machine tools, characteristic of Nylatron nylon, industry has long been and general processing equipment. Reductions in excess aware of its ability to reduce or eliminate lubrication, provide of 10 dBA have been recorded in actual filed use. longer wear and protect mating parts, reduce power The amount of noise reduction on any specific application required for start-and-stop operations, and provide depends upon such factors as the number of Nylatron gears corrosion resistance to alkalis, solvents, and certain dilute operating in the train, condition of the mating gears, and organic acids common in many industrial environments. general condition of equipment. This gear design manual covers only cut tooth Nylatron Reduced lubrication gearing, and does not apply to injection molded gearing. In certain applications, Nylatron gears need little or no Since the operating characteristics of Nylatron nylon gears lubrication, and they still retain their quiet, long-lasting, differ, often significantly, from those of metal gears, the smooth-running, wear-resistant characteristics. Also, distinct properties of Nylatron nylon must be recognized Nylatron gears can significantly reduce operating costs by and carefully considered at the beginning of the design eliminating product rejects that can be caused by lubricant process. contamination. The purpose of this manual is to furnish the basic material It should be noted, however, that although Nylatron nylon properties and design parameters which will allow correct gears can function dry in many applications, they will almost design, manufacture, installation, and use of Nylatron nylon always operate more efficiently with standard lubrication. gears. In particular, it is suggested that the section on backlash be very carefully read to insure that proper Longer Wear backlash allowance is designed into each gear mesh, and to Due to a unique combination of properties not found in insure that the gear is properly adjusted for backlash during metal or phenolic materials, Nylatron gears can provide installation. Failure to utilize the proper backlash will result significantly longer wear life in many applications. Not only in field problems with the finished gear. do Nylatron gears wear longer, they improve the wear life of The design and property data presented in this manual is mating parts. based upon years of plastics engineering and testing in actual field conditions. In a continuing extensive testing Corrosion Resistance program being conducted at The Polymer Corporation Nylatron gears cannot rust. They are unaffected by most of Technical Center, gear design and operating parameters not the commonly encountered alkalis, solvents, and some previously available on Nylatron nylon and other materials dilute organic acids. And, unlike phenolic gears which may are being determined. This design manual incorporates the swell from contact with certain hydrocarbons, Nylatron latest data. gears are unaffected by most lubricating oils and greases. Materials Smashup Protection Over many years of experience utilizing a wide variety of Nylatron gears can serve as a sacrificial gear in a high-cost thermoplastics for gearing, it has been determined that gear train. Overloads and smashups may cause Nylatron Nylatron GSM is the most suitable material for general gear gears to fail without causing serious damage to the more applications. The design parameters outlined in this manual expensive sections of the equipment. are based solely on Nylatron GSM nylon and include Reduced Power Requirements comparative values for other materials. Nylatron nylon gearing often requires less power to Nylatron GSM nylon, which contains finely divided operate than metal and phenolic gearing due to its lower particles of molybdenum 'disulphide solid lubricant uniformly coefficient of friction and lighter weight. dispersed throughout to provide extra surface lubricity, is produced by a casting process which can produce gear ring Increased Speed blanks up to 84" in diameter. Cast Nylatron segments are In some types of equipment, Nylatron gears have allowed used for larger gears. Gears with a circular pitch as large as increases in machine speeds and production rates which 3" have been manufactured from Nylatron nylon. were not possible with other gear materials. On paper drying equipment at a major American paper mill, dryer speeds were increased from 800 ft. per minute to 1800 ft. per minute after the installation of Nylatron gears. Similar equipment is reportedly operating at speeds in excess of 2500 ft. per minute.

130

PLASTICS GEAR DESIGN

Properties of Nylatron GSM Nylon Determining Successful Operation By Gear Testing

ASTM The design data presented here plus operating parameters Property Units No. Value for specific applications can determine the probability of Specific Gravity - D-792 1.15-1.17 successful operation for Nylatron nylon gearing. Tensile Strength, 73°F psi D-638 11,000-14,000 While our testing program has provided reliable data we recognize there are many variables and unknowns in actual Elongation, 73°F % D-638 10-60 practice. So called "identical equipment" can produce a Tensile Modulus of wide assortment of results. Therefore, it is recommended Elasticity, 73°F psi D-638 350,000-450,000 that test gears be installed on the specific equipment and Compressive tests be closely monitored. This will insure that the gear has Strength psi D-695 been properly designed, manufactured and installed. Should an unforeseen problem develop the cause can be identified @0.1% Offset 9,000 and the necessary adjustments made. @1.0% Offset 12,000 Shear Strength, 73°F psi D-732 10,500-11,500 Operating Limitations Hardness The properties of Nylatron nylon must be fully understood in order to properly design an operational Nylatron nylon (Rockwell), 73°F - D-785 R112-120 gear. The following limitations are dictated by the basic Tensile Impact, 73°F fl.lb./ - 80-130 properties of Nylatron material. in.' Load Capacity Deformation The load-carrying capabilities of Nylatron gears are

Under Load generally lower than metallic gears. Nylatron gears can 122° F, 2000 psi % D-621 0.5-1.0 momentarily carry higher tooth loadings since under high Coefficient of Friction tooth loading, deflection takes place. This deflection (Dry vs. Steel) Dynamic - - .15-.35 distributes the load over 2 or more teeth, which can more Heat Distortion Temp. easily handle the load than a single tooth. This is not recommended for general operation, but does provide a 66 psi OF D-648 400-425 safety factor in the gear train. 264 psi OF D-648 200-425 Temperature Melting Point OF D-789 430 ± 10 Nylatron gearing is generally limited to a maximum Continuous Service temperature of 200-225°F. Temp. (In Air) OF - 200-225 Nylatron nylon has a coefficient of linear thermal Flammability - D635 Self-extinguishing expansion 10 times that of metals. This expansion, under Coefficient of normal conditions of operating temperature, will decrease Linear Thermal in./ the backlash of Nylatron gears. Therefore, when replacing 5 metal gears with Nylatron nylon gears, increased backlash Expansion in.°F D-696 5.0 X 10· is an absolute necessity for successful operation. Water Absorption 24 hours % D-570 .6-1.2 Moisture Saturation % D-570 5.5-6.5 Nylatron nylon does absorb some moisture, and will therefore increase slightly in size. However, most gears are

Resistant to: of such a heavy section that moisture pickup is extremely Common solvents, hydrocarbons, esters, ketones, alkalis, dilute slow and does not require any special consideration when acids. designing the gear. Again, increased backlash compensates Not Resistant to: for growth due to moisture. Phenol, formic acid, concentrated mineral acids. Speed Nylatron gearing can operate up to pitch line velocities of 4,000 to 6,000 fpm. Continuous lubrication should be used under high speed conditions.

131

PLASTICS GEAR DESIGN

Gear Design and Installation circle (From Table 4) Sat = allowable bending stress A continuing testing program has developed a vast (75% of fatigue bending stress), psi. amount of significant data important to gear design. Fatigue Op = pitch diameter of gear, in. life tests on "cut tooth" spur gears have been concluded on v = pitch line velocity, fpm four diametral pitch series. The resulting S-N curves are = .262 X Dp n shown below and were derived using the following formulas. n = gear speed, rpm

1. OB - Fatigue Bending Stress Lubrication Os =.EE.. fy In many cases, the use of Nylatron gears can significantly reduce lubrication requirements. During installation, initial lubrication is always suggested to aid the run-in of the gear. 2. Ft - Safe Tangential Force Afterward, periodic lubrication on a maintenance schedule Ft=Sat fy which ties in with other pieces of equipment can be utilized. p If absolutely necessary, dry operation is possible, but may cause a reduction in gear efficiency; the wear rate, for example, may increase. For any anticipated long-term dry 3. T - Safe Torque operation, careful field testing is a prerequisite for T = DP Ft or HP x 63,000 successful operation. 2 rpm If the application is a high speed gear (4,000 to 6,000 sfpm), it is suggested that continuous lubrication be utilized to not only lubricate the contact surfaces, but, more 4. HP - Horsepower Capacity importantly, to dissipate the increased temperatures which Ftv Tn will result from hysteresis and friction. HP= 33,000 or 63,000 Most industrial lubricants will not affect the performance of Nylatron nylon gearing. However, partially saponified soaps where: or lubricants based on polyglycols should be avoided. B = fatigue root bending stress, psi. Tables 1, 2 and 3 list torque and horsepower capacities for F = tangential force at pitch circle, lbs. Nylatron GSM nylon gears based on three common P = diametral pitch lubrication systems - continuous oil, daily greasing and f = gear face width, in. weekly greasing. y = tooth-form factor for load applied near pitch

P.S.I. 0 PITCH LINE VELOCITY 2,000 FT./MIN.

8,000 TEST GEARS □ 16P, 72T 0 10P, 45T

Cl) t:::. SP, 36T Cl) w cc 5P, 18T I- C/) 6,000 (!) 0"-._0 z cz ------00 w ----- 0 0...... _0 III l­ A A o 0 0 M 0 4,000 cc -----8. -- 0 LIFE CYCLES 2,000 105 10 7 Fig. 1 - Fatigue Root Bending Stress vs. Life Cycles at 2,000 ft./min. for Nylatron Gears

132

PLASTICS GEAR DESIGN

TABLE 1 Capacity of Nylatron® GSM Nylon Gears - Lubricated

Pitch, P.A. 16 10 8 5

B, psi 6170 4650 3830 3252 Sat, psi 4630 3490 2870 2439 Sat/P 289 349 359 488

At pitch line velocity of 2,000 ft/min for face width of 1 inch, the capacity of Nylatron nylon gears of 20° full depth with oil lubrication at 120°F. is calculated.

No. of y Teeth Ft T H.P. Ft T H.P. Ft T H.P. Ft T H.P. lbs in-lbs lbs in-lbs lbs in-lbs lbs in-lbs 18 521 151 84.6 9.15 182 163.8 11.03 187 210.4 11.33 254 457.2 15.39 24. 572 165 123.8 10.00 200 240.0 12.12 205 307.5 12.42 279 668.4 16.88 28. 597 173 151.4 1 0.48 208 291.2 12.61 214 374.51 2.97 291 814.0 17.62 (30). 607 - - - 212 318.0 12.85 ------(32) .616 ------221 442.0 13.39 - - - 34 .628 181 191.9 10.97 219 372.3 13.27 225 478.1 13.64 306 1040.5 18.55 45 .678 196 276.4 11.88 237 533.3 14.36 2 43 682.8 14.72 325 1487.3 20.03 (48) .680 197 295.5 11.94 ------60 .713 206 386.3 12.48 249 747. 0 15.09 256 960.0 15.52 348 2087.1 21.09 75 .735 2 12 496.1 12.85 257 963.8 15.58 264 1238.0 16.00 359 2685.9 21.70 150 .779 225 1055.0 13.64 272 2040.0 16.48 280 2626.0 16.97 380 5692.0 23.00 300 .801 231 2165.0 14.00 280 4200.0 16.97 288 5400.0 17.45 391 11720.0 23.68 Rack. 823 238 - 14.42 287 - 17.39 295 - 17.88 402 24.30

Note: 1. For gears with full root radius add 5.4% to the capacity. 2. For gears with initial greasing only subtract 25.6% from the capacity. TABLE2 Guide for Nylatron Nylon Capacity: Daily Greasing Schedule (1800 rpm or less)

Diametral pitch, P 16 10 8 5 Endurance stress, B 5900 4450 3670 3040 Design stress Sat, psi 4390 3310 2730 2260 Sat/P 274 331 341 452 Ft T hp Ft T hp Ft T hp Ft T hp Number of teeth y lb lb-in. lb lb-in. lb lb-in. lb lb-in. 18. .521 143 80.4 2.3 172 155 4.4 178 200 5.7 235 423 12.1 24 .572 157 117 3.3 189 227 6.5 195 293 8.4 259 622 17.8 28 .597 164 144. 4.1 198 277 7.9 204 357 10.2 270 756 21.6 30 .607 166 156 4.5 201 302 8.6 207 388 11.0 274 822 23.5 32 .616 169 169 4.8 204 326 9.3 210 420 12.0 274 877 25.1 34 .628 172 183 5.2 208 354 10.1 214 455 13.0 284 45 .678 185 260 7.4 224 504 14.4 231 650 18.6 306 48 .680 186 279 8.0 225 540 15.4 232 696 19.9 307 60 .713 195 366 10.5 236 243 322 75 .735 201 471 13.5 243 251 332 150 .779 213 258 266 352 300 .801 219 265 273 362 Rack .823 225 272 281 372

Note: 1. Rating at 1800 rpm was given. At a slower speed, it is proportional to the speed. 2. The design capacity figures apply also to oil drip-lubricated gears.

133

PLASTICS GEAR DESIGN

TABLE3 Guide for Nylatron Nylon Capacity: Weekly Greasing Schedule (1200 rpm or less)

Diametral pitch, P 16 10 8 5 Endurance stress, B 4350 3280 2700 2240 Design stress Sat, psi 3240 2440 2010 1670 Sat/P 202.5 244 251 334 Ft T hp Ft T hp Ft T hp Ft T hp

Number of teeth y lb lb-in. lb lb-in. lb lb-in. lb lb-in. 18 521 106 59.6 1.1 127 114 2.2 131 147 2.8 174 313 6.0 24 572 .116 87.0 1.7 140 168 3.2 144 216 4.1 191 458 8.7 28 .597 121 106 2.0 146 204 3.9 150 262 5.0 199 557 10.6 30 .607 123 115 2.2 148 222 4.2 152 285 5.4 203 609 11.6 32 .616 125 125 2.4 150 240 4.6 155 310 5.9 206 659 12.5 34 .628 127 135 2.6 153 260 5.0 158 336 6.4 210 45 .678 137 193 3.7 165 371 7.1 170 478 9.1 226 48 .680 138 201 3.9 166 398 7.6 171 513 9.8 227 60 .713 144 270 5.1 174 179 238 75 .735 149 349 6.6 179 184 245 150 .779 158 190 196 260 300 .801 162 195 201 268 Rack .823 167 201 201 275

Note: HP rating at 1200 rpm was given. At a slower speed it is proportional to the speed.

Tooth Form Table 4 Field experience has shown that Nylatron nylon gearing Tooth Form Factor Load Near the Pitch Point can operate successfully utilizing any of the standard tooth Number of 20°F Full forms in use today. This is especially important in replacing existing gearing on operating equipment. Teeth 14½° Depth 20° Stub 14 - - 0.540 When designing new equipment, it is suggested that consideration be given to the 20° pressure angle full depth 15 - - 0.566 tooth form. From available technical information, this 16 - - 0.578 appears to be one of the most useful for Nylatron gearing. 17 - 0.512 0.587 Our tests have shown that the load carrying capacity of 18 - 0.521 0.063 20°P.A. Nylatron GSM sp r gears is approximately 15% 19 - 0.534 0.616 greater than a gear of 14 !2° P.A. At the same load 20°P.A. gears will offer 3.5 times longer life than 14 ½° P.A. gears. 20 - 0.544 0.628 22 - 0.559 0.648 24 0.509 0.572 0.664 Other Engineering Materials 26 0.522 0.588 0.678 Although superior test results have been achieved with 28 0.535 0.597 0.688 Nylatron GSM nylon we recognize the need for and use of other materials. Table 5 lists materials that have been tested 30 0.540 0.606 0.698 under the same conditions as Nylatron nylon and shows 34 0.553 0.628 0.714 their relative strength factors for the three lubrication 38 0.566 0.651 0.729 methods. 43 0.575 0.672 0.739 To compare Nylatron nylon with another material multiply 50 0.588 0.694 0.758 the torque and horsepower values for Nylatron spur gears 60 0.604 0.713 0.774 (Table 1) by the strength factor of the material in question (Table 5) for the equivalent torque and horsepower value. 75 0.613 0.735 0.792 100 0.622 0.757 0.808 Example: The strength factor for phenolic is listed at 0.89. The torque and horsepower values for a 5 pitch, 45 tooth 150 0.635 0.779 0.830 Nylatron gear are 1,487.3 and 20.03 respectively. 300 0.650 0.801 0.855 1,487.3 x 0.89 = 1,324 in.fibs. torque Rack 0.660 0 .823 0.881 20.03 x 0.89 = 17.8 horsepower

134

PLASTICS GEAR DESIGN

Table 5 TABLE 7 Strength Strength Life Factors for Nylatron Nylon Spur Gears Factor Factor Strength Number 16 10 8 5 (Oil Initial Factor Material Lubrication) Greasing) (Dry) of cycles pitch pitch pitch pitch 1 million 1.26 1.24 1.30 1.22 Nylatron® 10 million 1.0 1.0 1.0 1.0 GSM Nylon 1 0.74 0.39 MC® 901 1 0.74 0.39 30 million 0.87 0.88 0.89 0.89 Nylatron NSM 0.95 0.79 0.78 Acetal 0.82 Gear Sound Measurement Nylon 101 0.92 Zytel* ST801 0.89 Gear noise is a major problem in many industries but so Nylatron GSM-P 0.83 many factors are involved in noise analysis that it is not Nylatron GS 0.97 0.88 practical to cover the subject here. The design of the entire Phenolic "C" 0.89 0.76 system, for example, must be thoroughly investigated to Nylatron NSB 0.68 0.39 isolate noise sources which can then be addressed with Ultra-Wear® suppression techniques. UHMWPE 0.59 With few exceptions Nylatron gears run quieter than gears UHMWPE- of bronze, cast iron and phenolic. Metal gears can be Glass-Filled 0.59 engineered and manufactured to run quietly, however, the UHMWPE- cost of producing high quality gears may be prohibitive. Maly-Filled 0.55 Test results are shown below in Figure 2. All test gears Minion* 10A40 0.47 were 1OP, 20° PA, 45 teeth, running with a hardened steel Bronze SAE 65 1.05 0.19 pinion of 25 teeth, pitch line velocity 2000 fpm, gear teeth Cast Iron, Class 30 1.87 0.43 greased.

*Registered trademark of DuPont Corporation See Spur Gear Worksheet Page A-7.

Velocity Correction Factors 105 The rated torque and horsepower values in Table 1 are for pitch line velocity of 2,000 ft./min. Table 6 provides correction factors for other speeds. 100 Example: A 5 pitch, 45 tooth Nylatron gear is to operate at 1,000 ft./min. The correction factor is 1.18. The rated torque and horsepower value for this gear at 2,000 ft./min. is 90 20.03 x 1.18 = 23.6 horsepower ...J C z ro0 / ' TABLE 6 0 85 en I Velocity Correction Factors to.

Velocity-fpm Correction Factor 500 1.38 80 1000 1.18 2000 75 0 3000 0.93 B to. 0 10 20 30 40 (Nm) 4000 0.90 5000 0.88 Q z 0 100 200 300 400 "(.')5: TORQUE (in/lbs) a3C!l

Life Service Factors Fig. 2 - Sound levels of gears of different materials meshing The rated torque and horsepower values shown in Tables 1, with a steel pinion. 100P, 20° PA, 45/25 teeth pitch line 2 and 3 are based on 10MM cycles. Table 7 lists service velocity 2000 fpm. factors for three typical cycle ranges.

135

PLASTICS GEAR DESIGN

SPUR GEAR DESIGN WORKSHEET USING NYLATRON NYLON GEAR DESIGN FORMULAS

Required Application Data Design Calculations for Nylatron GSM (Page 5) Diametral Pitch p 5 Ft - Safe Tangential Force (Formula 2) 30 Number of Teeth Ft= S xfxy Pressure Angle 20° p 1½ Face Width, Inches f Ft = .1illL X L§_ X 0.606 Input Speed RPM n 750 Ft =

Lubrication-Qi1/Grease Oil Input Torque iT 1260 or T - Safe Torque (Formula 3)

Input Horsepower iHP 15 = or HP x T Dp- F 1 63,000 (Can be calculated) 2 rpm T = X Calculated Data T = 1332 in. lbs. Pitch Diameter Dp 6.000 No. of Teeth p HP - Horsepower Capacity (Formula 4) HP = Ft xv or T x n -- -- Input Torque iT 1260 33,000 63,000 iHP x 63,000 HP _ 444 x 1179 or 1332 x 750 - 33,000 63,000 n

Input Horsepower iHP 15 iTx n 63,000 Alternate Material (Table 5) Strength Factor (Table 5) Pitch Line Velocity v 1_17_9 Equivalent Torque = T x Factor = x _ .262 x Dp x n eT = in. lbs. Equivalent HP = HP x Factor = x _ From Design Manual or Table Below eHp =--- Tooth Form Factor (Table 4) y 0.606 Bending Stress Sat 2439 (See Table 1, Notes 1 and 2 for Sat 488 Tooth Form and Lubrication Corrections) p Velocity Correction Factor 1.18 (Table 6) Sat Resulting Torque =Tor eT x Factor = 1332 X 1.18 Pitch Sat p rT = 1572 in. lbs. 2 1994 997 Resulting Horsepower = HP or eHP x Factor 3 2345 781 = 16 X 1.18

4 2410 603 rHP = 19

5 2439 488

6 2675 446 Service Factor _ (Table 7)

8 2870 359 Service Torque = rT x Factor 10 3490 349 = x _

12 3890 324 sT = _

16 4630 289 Service Horsepower= rHP x Factor

20 5005 250 = x _ sHP =

136

PLASTICS GEAR DESIGN

Backlash Mating Gear Materials One of the most frequent design errors made in converting For best operation, a Nylatron gear should be mated with from a metal gear to a plastic gear is not allowing sufficient a metallic gear as this arrangement promotes heat backlash. Nylatron nylon has a coefficient of linear thermal dissipation. If an all-plastic gear system must be used the expansion 1O times that of metals. Accordingly, it is combination of nylon and acetal is recommended, however, necessary to make additional allowances for this expansion thorough testing is advised to qualify design and materials. in the design and manufacture of Nylatron gears. If the In certain applications, gear systems with a Nylatron-to­ appropriate backlash is not allowed in the Nylatron gear, Nylatron mating arrangement have operated successfully. interference may occur during operation. This will cause Because of its resiliency, Nylatron gearing can operate additional temperature rise and lead to the ultimate failure of successfully with gears which have previously been in the gear. See Figure 3. service if these gears are in reasonable operating condition. The following formula can be used to calculate the Nylatron nylon will conform to slightly mismatched surfaces, necessary operating backlash for Nylatron gears. operate with minor machining errors, and continue to operate normally without the accelerated wear or breakdown that occurs with other materials. Mating gears of Backlash = .100" cast iron, steel and aluminum have been most successful. P (diametral pitch) Care should be taken to check the gear train to insure that bearings and other mountings are in good operating condition. Backlash is usually attained by cutting it into the gear. The preferred method is to increase the center distance between Design Data For Other Gear Types the mating gears and cut the gears without backlash. This, The design formulas shown on page 5 may be modified for however, is limited to new designs. If the set of gears is to other gear types. be replaced, the Nylatron gear should be cut without backlash in order to provide maximum tooth strength. The Helical Gears mating metal gear should be cut to provide proper backlash In Formula #1 use the equivalent number of teeth for a when the gears are assembled. If only one gear is being spur gear and the normal diametral pitch. replaced with a Nylatron gear, the nylon gear must be cut Equlgear teeth (cos )3 with the proper backlash. Normal diametral pitch = Pt If the Nylatron gear is to be installed in a gear train with adjustable centers, care must be taken to insure that the cos gear mesh has been checked for the appropriate backlash N = Number of teeth (helical gear) prior to operating the gear. It is suggested that the Nylatron cos = Cosine of helix angle gear and the mating metal gear be checked at 90° intervals through one complete rotation to insure both gears are Pt = Transverse diametral pitch (Pitch in the plane of running true and are not mounted on bent shafts or rotation) defective bearings. Bevel Gears In Formula #1 use the equivalent number of teeth for a spur ...\.,\,.,.,,,--Backlash gear. ,,,, ,, Equivalent number of = N '\ spur gear teeth cos

N = Number of teeth (bevel gear) cos = cosine of pitch angle Worm Gears This type of gear is subjected to higher frictional heat GEAR BACKLASH Backlash for Nylatron& GSM = .100" build-up than other gear tooth forms because of the sliding p action of the worm. The worm is usually metal and since SPECIAL NOTE only a short length of it is in mesh with the worm gear, heat The lack of proper backlash is the most common cause may develop rapidly depending on lubrication load and of nylon gear failure. Backlash should be checked on speed. installation through a full rotation of the nylon gear. It is recommended that thorough testing be conducted for Nylatron worm gear applications. Roller Chain Sprockets Field evaluations to date indicate that Nylatron GSM nylon roller chain sprocket performance is equal to or better than metal sprockets. Increased chain life is an added advantage. Thorough testing is recommended.

137

PLASTICS GEAR DESIGN

/

,,,...... / j/ " \ ,.\, l '- ..,. ;m I,e' - '\ \ I J '- " I, \ \ \ "'

Nylatron Nylatron Metal Nylon Metal Nylon

Fig. 4 - Nylon is fitted on single flange metal hub. Bolt head Fig. 5 - This assembly uses metal flanges on both sides of is seated in nylon blank; bolt is threaded into metal hub. the nylon for increased rigidity in heavy duty applications. Maximum span from bolt to bolt center lines should not The amount of interference fit between nylon gear and metal exceed 12". hub should insure it remains tight when normal operating temperatures are reached.

Metal Hubs For Nylatron gearing exceeding 8" in diameter or for gears in HP = horsepower transmitted relatively severe service, it is suggested that a metal hub be utilized. Refer to Figures 4 and 5 above. n = gear speed in rpm Fasteners should have a locking device such as lock washers, nuts and/or bonding products. R = mean keyway radius in inches Keyways Keyways can be used to drive an all-Nylatron gear. With this construction method, however, a check should be made to (See Figure 6) insure that the keyway has the required load carrying capabilities. The keyway always should have radiused When installing a Nylatron gear be certain that the sharp corners to reduce stress concentration. The minimum corners of the key are chamfered. If not chamfered, the keyway area is determined from the following formula: key will broach the fillet radius and may cause the gear

to fracture. A= 20 HP nR

A = minimum keyway area (length x height in inches)

138

PLASTICS GEAR DESIGN

ILi µ:...L--"---"--'c...<...<....,_._,'--'! ! Lh

Radius up to 'la in. key - 1/32 Radius '/, in. key and above - 1/16 Radius

Fig. 6

Set Screws Self-locking set screws can be utilized in an all-Nylatron gear, but consideration must be given to the construction and the type of service required. In the event that severe service may be encountered, it is suggested that a metal hub be utilized. Dn installation, care should be taken when tightening the set screw. The maintenance mechanic will realize a different "feel", and may, therefore, overtighten the screw. It is suggested that the set screw be hand tightened, then tightened one-half a rotation.

NOTES Inspection Inspection of the finish dimensions should be made after the part has cooled to room temperature. This will avoid measurement errors caused by thermal expansion. Resilience of the material must be taken into consideration when using inspection tools. Literally, a "feel" must be developed for the softness of the material to prevent squeezing the nylon with a micrometer or other measuring device. If too much pressure is applied, indications of smaller outside measurements and conversely larger inside measurements than the actual size of the part will result. Measurements must be made with care to apply only sufficient pressure to prevent compressing or expanding the material. Air gauges and optical comparators can be used to advantage. Occasionally a bore in a gear may be found to be undersize when the gear is completed and cooled to room temperatures. Depending on the tolerance limits specified, a secondary finishing cut in the bore may required.

139

U.L. FLAMMABILITY RATINGS

UL 94 Flame Class categorized by this T.M., it enables the In accordance with the small-scale burning product designer to more accurately match tests given in the "Standard Tests for materials to end-product flame requirements. Flammability of Plastic Materials For Parts In Because UL's individual product standards Devices and Appliances", materials are rarely specify a flame class, the following tested and classified as 94HB, 94V-0, 94V-1, table which lists test criterion that ascertains 94V-2 and/or 94-5V. the classification status should be of use to you in (1) quickly determining what products 94 HB Horizontal Burning Test fulfills the designer's needs. A testing procedure that closely parallels 94-SV Vertical Burning Test ASTM D-635. It's used by UL to obtain and control the burn rate of materials destined for The 94-5V is the most stringent flame test use in listed products. Polymers recognized UL applies to our products. Generally it's an as 94HB are generally specified in end-use requirement, however, a yellow card applications where some control of recognition can be obtained if both plaques flammability is desirable; however, they will and small bar specimens are tested by UL not satisfy the need if flame extinguishment is with acceptable results. Once the 94-5V required. recognition is obtained, it's universally accepted within UL and the test may be Materials that are classified as 94Hb shall- waivered where it is specified for final (A) Not have a burning rate exceeding 1.5 product approval ... providing of course the inch/minute over a 3 inch span for part's minimum thickness is not less than the specimens having a thickness of 0.120 minimum thickness initially tested for inch and above. recognition. (B) Not having a burning rate exceeding 3.0 A 94-5Vyellow card recognition is of value inch/minute over a 3 inch span for to B-W because this particular test appears specimens having a thickness under in the regulations governing line wired 0.120 inch. audible signal appliances (smoke detectors, (C) Cease to burn, before the flame reaches etc.), air conditioners, stationary and fixed the 4 inch reference mark but shall not electrical tools, and electronic data comply with 94V-0, 94V-1 or 94V-2 requirements. processing units and systems to name a few. Materials classed 94-5V shall not have any 94V-0, 94V-1, 94V-2 Vertical Burning Test specimen which- A small-scale, vertical test method used by (A) Burn with flaming and/or glowing UL to determine how well a material resists combustion for more than 60 seconds ignition and if it does ignite, what is its after the fifth application of flame. tendency to propagate flame. 94V-0, (B) Drip any particles 94V-1, and 94V-2 are flame retardant (C) Are destroyed to a significant degree* in classifications and once polymers are so the tested area.

140

COMPARATIVE MATERIALS CHART The following chart is a fold out and is intended to be a wall chart.

Test Method Nylatron° GS Nylatron® NS Property - - Units ASTM Nylon 101 Nylon Nylon

- Product Extruded, Unfilled Extruded, MoS2 filled Extruded, solid Type 6/6 lubricant filled Type 6/6 Description Type 6/6 Mechanical 1 Specific Gravity - D792 1.14-1.15 1.14-1.18 1.18 2 Tensile Strength, 73°F psi 0638 9,000-12,000 10,000-14,000 10,500 3 Tensile Modulus of Elasticity, 73°F psi D638 250,000-400,000 450,000-600,000 408,000 4 Elongation, 73°F % D638 20-200 5-150 10 5 Flexural Strength, 73°F psi D790 12,500-14,000 16,000-19,000 14,500

6 Flexural Modulus of Elasticity, 73°F psi D790 350,000-410,000 400,000-500,000 400,000 7 Shear Strength, 73°F psi D732 9,600 9,500-10,500 9,000 8 Compressive Strength, 10% Def. psi D695 12,000 12,000-13,000 12,500 9 Compressive Modulus of Elasticity, 73°F psi D695 - - - 10 Coefficient of Friction (Dry vs. Steel) Dynamic @ - - .17-.43 .15-.35 .17-.38 11 Hardness, Rockwell, 73°F - D785 Rll0-120 Rll0-125 116 12 Durometer, 73°F - D2240 D80-85 D80-90 86 13 Tensile Impact ft. lb./ in. Dl822 90-180 50-180 122 Thermal 14 Coefficient of Linear Thermal Expansion in. /in. I °F D696 5.5 X 10-5 3.5 X 10·5 5.5 X 1()-5 15 Deformation Under Load (122°F, 2,000 psi) % D621 1.0-3.0 0.5-2.5 0.65 16 Deflection Temperature 264 psi OF D648 200-450 200-470 200 17 Tg-Glass transition (amorphous) OF - - - - 18 Melting Point (crystalline) OF D789 482-500 482-500 490 ±10 19 Continuous Service Temperature in Air (Max.) OF - 220 220 220 Electrical 20 Dielectric Strength Short Time Volts/mil Dl49 300-400@ 300-400@ - 21 Volume Resistivity OHM-CM D257 4.5 X 1013 2.5 X 1013 - 22 Dielectric Constant, 60Hz - Dl50 4.1 - - 23 103Hz - Dl50 4 - - 24 105Hz - Dl50 3.4 - - 25 Dissipation Factor, 60Hz - - - - 26 lOHz - - - - Chemical 27 Water Absorption Immersion 24 Hours % D570@ 0.6-1.5 0.5-1.4 1 28 Saturation % D570 7-9 6-8 7.5 29 Acids, Weak, 73°F L L L 30 Strong, 73°F u u u 31 Alkalies, Weak, 73°F A A A 32 Strong, 73°F A A A 33 Hydrocarbons-Aromatic, 73°F A A A 34 Hydrocarbons-Aliphatic, 73°F A A A 35 Ketones, 73°F A A A 36 Ethers, 73°F A A A 37 Esters, 73°F A A A 38 Alcohols, 73°F A A A 39 Inorganic Salt Solutions, 73°F A A A 40 Continuous Sunlight, 73°F L L L

141

COMPARATIVE MATERIALS PROPERTIES

MC®901, 907 & Fluorosint® ® ® Fluorosint Nylatron® GSM Nylatron® NSM Acetron GP Acetron® NS Ertalyte® 207 500 Nylon Nylon & Delrin* Acetal Acetal DelrinAF* PET PTFE PTFE E,1ruded, Internally Extruded, Semi-crystalline Synthetic mica-filled Synthetic mica-filled stabilized, natu Extruded, unfilled lubricated acetal Teflon-acetal Thermoplastic PTFE Lexan* orenhanced filled T•ype 6 Polyester PTFE

1.16 1.15 1.41-1.42 1.44 1.54 1.39 2.25-2.35 2.25-2.35 1.2 12,000 10,000-12,000 8,800-12,000 7,000-8,000 7,600 12,400 1,000-1,500 750-1,200 9,000-10,500 400,000 450,000 410,000-520,000 350,000 420,000 423,000 300,000-450,000 375,000-600,000 320,000 50 50-70 30-65 10-30 22 20 3-25 1-10 60-100 - 16,000 -17,500 16,000 13,000-15,500 7,000 10,500 2,000-3,000 1,500-2,500 11,000-13,000 350,000-450,000 400,000 375,000-550,000 380,000 340,000 - 250,000-350,000 425,000-550,000 375,000 - 10,500-11,500 10,000 7,700-9,500 6,000 8,000 - - 9,200 - - 16,000-18,000 14,000 13,000 15,000 - - 11,000 - - 275,000-325,000 240,000 400,000 - - 315,000 225,000-275,000 .16-.35 .13-.16 .25 .20 - - .04-.2 .1-.2 - R120 115 R119-122 R116 R118 M93-100 R40-60 R45-65 R118 - - 86 - D83 - D87 D64-74 D64-74 - 150 7 40-90 35 50 50 - 225-300 5 5 5.Q X lQ--5 5.0 X 10·5 6.7 X 10·' 4.7 X 10·5 5.8-6.8 X 10·5 3.3 X 10· 3.25-4.50 X lQ 1.25-1.50 X 10·5 3.9 X lQ--5 0.5-1.0 0.9 0.3-1.0 0.6 0.6 - 2.25-2.85 0.8-1.1 0.3 ® 200-425 200 230-265 270 244 215 200-220 240-300 280-290 ------293

430±10 329-347 347 347 49 621±9 621±9 - " 180-200 180 180 180 212 500 500 250 � 500-600@ - 380-500@ 320 400 385 200-250 275-300 >400 i 1 X 1014-1 X 1015 - 16 11 1 - 3 X 10 5.5 X 10 >1012 >10 '1 2.1 X 1016 - .·. 2.65-2.85 2.85-3.65 - - - - 3.17 - - 3.1 - - 2.9-3.6 - •' 3.7 3.7 3.7 - 3.7 - - - 2.9-3.6 I 2.96 .•.. 3.1 ------.0009 ' ------

30% Glass Filled Techtron" Torlon* Torlon* Torlon* illtem* illtem* Polysulfone PEEK PEEK PPS 4203 4301 5030 1000 2300 Extruded, unfilled Extruded, Extruded, Extruded, Extruded, Extruded, Extruded, Extruded, Extruded, polyamide-imide polyamide-imide polyetherimide

53 9 - 644 644 540 - - - - - 300 480 480 425 475 475 475 338 338 425 480 - 540 580 - 840 830 770 "' "' 1 5 X 10 4.9 X 10 - 4.5 X 1016 8 X 10W 3 X 10"' 6 X 1016 6.7 X 10 ; 3.0 X lQW 3.15 3.30 - 3.0 - - - - 3.1 - - - 4.2 6.0 4.4 3.15 - - 3.25 - 3.0 3.9 5.4 4.2 - - .0011 - - 0.0013 - - 0.022 - - - - - 0.0010 - - 0.023 - - 0.3 0.15 0.11 0.01 0.28 0.24 0.25 .16 ------1.25 .90 A A A A A A A A A A L L A A A A A A A A A A L L L L L A A A A u u u L L L A A A A A A L L A A A A A A A A A u A A A A A A A A L A A A A A A A A u A A A A A A A A L A A A A A A A A A A A A A A A A A L - - L L L L - -