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Tough Or Strong? Short Or Long? Dialing in Mechanical Properties THERM0PLASTIC ELASTOMERS • STRUCTURAL • WEAR CONDUCTIVE • COLOR • FLAME RETARDANT Tough or Strong? Short or Long? Dialing in Mechanical Properties Karl Hoppe Senior Product Development Engineer Strength YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Stiffness YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Impact YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Structural Composites Formula YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Change in Resin Addi/ves Properes Structural Additives: Foundation YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS In this Presentation YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Modifiers Fillers Modifiers YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Polymer Blends Impact Modifiers Polymer Blends YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS ABS brings • Improved flow • Chemical resistance • Cost reduction PP brings • Improved flow • Chemical resistance • Cost reduction PBT brings • Improved flow • Chemical Resistance Polymer Blends YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS PC brings • Toughness • Strength Nylon brings • Strength • Stiffness PC brings • Toughness • Dimensional stability Polymer Blends YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS PC/ABS PC ABS (RTP 2500 A) Specific 1.19 1.15 1.05 Gravity Tensile 59 MPa 59 MPa 45 MPa Strength Notched Izod 850 J/m 740 J/m 250 J/m Impact Polymer Blends YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Application: Housing for Hearing Tester Problem: Toughness and chemical resistance Solution: Polycarbonate/ABS Alloy Benefit: Strength and toughness of PC with the added chemical resistance of ABS Modifiers YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Impact proper/es Impact Modifiers Strength Sffness Impact Modifiers YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Impact Modified PA 6/6 PA 6/6 Specific Gravity 1.14 1.08 Notched Izod 55 J/m 900 J/m Impact Tensile Strength 80 J/m 45 J/m Flexural Modulus 2.8 GPa 1.8 GPa Impact Modified YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Application: Housing for Wireless Workstation Problem: Toughness and abrasion resistance Solution: Impact Modified PA 6/6 Benefit: Wear and abrasion resistance of Nylon 6/6 with added toughness from impact modifier Impact Modifiers YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Lose Performance Base resin Temperature Limitaons Chemical Resistance Environment UV Resistance Modifiers YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Stabilizers • Protect from – UV – Heat aging UV Stabilization YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS • Hindered Amine Light Stabilizers (HALS) – Protects polymer by stopping degradation reactions once they have started • UV Absorbers – Protects polymer by absorbing harmful UV light before the degradation reaction has started UV Stabilization Data YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS 30% Long Fiber (VLF) PP 120.00% 100.00% 80.00% 60.00% 40.00% 20.00% Tensile Strength Reten3on 0.00% 0 1250 2500 3500 4000 4500 UV Exposure - kJ/m2 HALS HALS + Absorber Heat Stabilization YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS • Heat stabilizers come in many forms – Slow down the degradation reactions of the polymer caused by heat – Can be for process stability or Long Term Heat Aging (LTHA) Heat Stabilization Data YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS 40% VLF PP 1000 Hour Heat Aging Tensile Izod Impact Temperature Reten/on Reten/on 140ºC +5.7% +9.9% 150ºC -4.7% -11.3% Typical Automotive requirements are ~+/- 25% In this Presentation YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Modifiers Fillers Fillers YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Beads (Glass) (photo: Potters, Inc.) Minerals (Talc) Fibers (Glass) Fillers YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Property change determined by: Aspect Rao Reinforcing Low Aspect Ratio YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS PC + 10% PC + 30% PC Aspect Ratio = 1 Glass Beads Glass Beads Specific 1.19 1.27 1.42 Gravity Tensile 59 MPa 55 MPa 48 MPa Beads (Glass) Strength (photo: Potters, Inc.) Notched 850 J/m 100 J/m 80 J/m Izod Impact Aspect Rao = 1 Flexural 2.4 GPa 2.6 GPa 3.4 GPa Modulus Low Aspect Ratio YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS PP + PP + PP 20% Talc 40% Talc Specific 0.91 1.05 1.25 Gravity Tensile 32 MPa 32 MPa 30 MPa Strength Minerals (Talc) Notched 47 J/m 45 J/m 34 J/m Izod Impact Aspect Rao = 2-50 Flexural 1.5 GPa 2.5 GPa 3.8 GPa Modulus Warp Control YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Shrink Rate x = Shrink Rate y Flat Part Low Aspect Ratio YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Application: Reusable Handling Container Problem: Dimensional stability Solution: Mineral filled Polypropylene Benefit: Low warpage High Aspect Ratio YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS PC + 30% PC + 30% PC Glass Glass Beads Fiber Specific 1.19 1.42 1.42 Gravity Tensile 59 MPa 48 MPa 124 MPa Fibers (Glass) Strength Notched 850 J/m 80 J/m 160 J/m Izod Impact Aspect Rao = 50-250 Flexural 2.4 GPa 3.4 GPa 7.6 GPa Modulus High Aspect Ratio YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS PP + PP+ 40% PP 40% Talc Glass Fiber Specific 0.91 1.25 1.22 Gravity Tensile 32 MPa 30 MPa 85 MPa Fibers (Glass) Strength Notched 47 J/m 34 J/m 108 J/m Izod Impact Flexural 1.5 GPa 3.8 GPa 6.9 GPa Aspect Rao = 50-250 Modulus High Aspect Ratio YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Application: Surgery Drill Guide Problem: Stiffness and dimensional stability Solution: Glass fiber reinforced Polycarbonate Benefit: Rigidity and tight tolerances Non-Uniform Shrink = Warp YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Shrinkage X1 & X2 ≠ X3 Warp Strength & Warp Control YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Shrinkage X1 = X2 = X3 Flat Part VLF Manufacturing Process YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Fiber Extruder/Die Puller Pelle/zer Extreme Aspect Ratio YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS PP+ 40% PP + 40% Short Long Glass Glass Specific 1.22 1.22 Gravity Tensile 85 MPa 118 MPa Strength Long Glass Fiber Notched 108 J/m 228 J/m Izod Impact Aspect Rao = 300+ Flexural 6.9 GPa 7.7 GPa Modulus Extreme Aspect Ratio YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Short Fiber Long Fiber Fiber Length ~ 1-2 mm 12 mm Secret to Success: The Skeleton YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS PA 66 + 60% VLF Seat Belt Tensioner Housing Polyamide 6/6 – 40% Glass Fiber YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS High Aspect Ratio YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS PEEK + 40% PEEK + 40% PEEK Glass Carbon Fiber Fiber Specific 1.30 1.61 1.45 Gravity Tensile Carbon 93 MPa 186 MPa 265 MPa Fibers Strength Notched 53 J/m 133 J/m 91 J/m Aspect Rao = 50-250 Izod Impact Flexural 3.8 GPa 13.8 GPa 30.3 GPa Modulus High Temperature Application YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Application: Brake Rotor Measuring Probe Problem: Casting replacement Solution: Carbon fiber reinforced PPA Benefit: High strength and stiffness High Temperature Polymers YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Amorphous Semi-Crystalline Polyetherimide (PEI) Thermal& CostIncreases Polyetheretherketone (PEEK) Polyethersulfone (PES) Polyphenylene Sulfide (PPS) Polysulfone (PSU) Polyphthalamide (PPA) Polycarbonate (PC) Polyethylene Terephthalate (PET) Acrylonitrile Butadiene Styrene (ABS) Polybutylene Terephthalate (PBT) Styrene Acrylonitrile (SAN) Polyamide (PA/Nylons) Polystyrene (PS) Acetal (POM) High Impact Polystyrene (HIPS) Polypropylene (PP) Acrylic (PMMA) Polyethylene (HDPE, LDPE, LLDPE) High Performance Engineering Commodity Chemical Structure YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Polyethylene Polyimide Tg -5 °F Tg 482 °F Amorphous Materials YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Flexural Modulus Vs. Temperature 14000 12000 10000 8000 6000 40% GF PSU 40% GF PES 4000 40% GF PEI Flexural Modulus, MPa 2000 0 0 50 100 150 200 250 300 350 400 450 500 Temperature, °F Semi-Crystalline Materials YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Flexural Modulus Vs. Temperature 18000 16000 14000 12000 10000 8000 40% GF PPA 6000 40% GF HTN 4000 40% GF PEEK Flexural Modulus, MPa 40% GF PPS 2000 40% GF TPI 0 0 50 100 150 200 250 300 350 400 450 500 Temperature, °F Elevated Temp Properties YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Mul/ple Temperature Tensile Stress/Strain 40% Glass fiber filled 40% Glass fiber filled Nylon 6/6 40% Glass fiber filled PPA Polypropylene 180 250 300 Typical DAM @ Typical DAM, -40 C Typical DAM, -40 -40 C C 160 Typical DAM @ Tyical DAM, 23 C Typical DAM, 23 C 23 C Typical DAM @ Typical DAM, 65 C 250 200 Typical DAM, 65 C 140 65 C Typical DAM @ Typical DAM, 121 Typical DAM, 176 107 C C C 120 200 150 100 150 80 Stress - MPa 100 60 100 40 50 50 20 0 0 0 0 0.02 0.04 0.06 0.08 0 0.02 0.04 0.06 0.08 0 0.02 0.04 0.06 0.08 Strain – mm/mm High Temperature Application YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS Application: Copier Bushings Problem: High temperature (>445°F) Solution: Aramid fiber reinforced TPI Benefit: Wear resistance Flexural Modulus YOUR GLOBAL COMPOUNDER OF CUSTOM
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