Ensinger Plastics Used in Aerospace Technology

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Plastics used in aerospace technology Content

4 Plastics in application 6 Product portfolio 7 Special materials 8 Application examples 10 Mechanical properties 12 Thermal properties 14 Electrical properties 15 Radiation resistance 16 Combustibility 17 Chemical resistance 18 Influence of processing on test results 19 Frequently asked questions 20 Quality management 22 Material standard values

Ensinger®, TECA®, TECADUR®, TECAFLON®, TECAFORM®, TECAM®, TECAMID®, TECANAT®, TECANYL®, TECAPEEK®, TECAPET®, TECAPRO®, TECASINT®, TECASON®, TECAST®, TECATRON® are registered trade marks of Ensinger GmbH. TECATOR® is a registered trade mark of Ensinger Inc. VICTREX® is a registered trademark of Victrex Manufacturing Ltd. TECAPEEK is made with VICTREX® PEEK polymer.

2 Technical plastics contribute to making ap- The characteristics of our plastics products plications more efficient and competitive in fulfil the detailed requirements of material many industrial areas. The aerospace industry specifications of final customers and system places high demands on materials. The im- suppliers in the aerospace industry. Safety as- pressive properties of high-performance plas- pects and reduced energy consumption are of tics include their low weight and fire behaviour. primary importance.

Benefits at a glance Ensinger quality in aerospace engineering ˌˌWeight savings of up to 60 % compared As requested by our customers, we have to aluminium reduce energy consump- checked and qualified a large share of our ma- tions terials against required specifications. We can ˌˌPlastics can be processed better than qualify additional materials on request. other materials ˌˌGreater freedom in component design Due to the special requirements of the aero- re-sults in reduced production and installa- space industry, Ensinger takes on responsi- tion costs bility for: raw materials receipt inspections, ˌˌGood chemical resistance raw materials specifications, composition spe- ˌˌInherent flame-resistance: High-perfor- cifications for individual articles, final inspec- mance plastics meet the requirements of tions, issuing of inspection certificates, and UL 94 -V0 and fire behaviour standards in much more. accordance with FAR 25.853 ˌˌFire behaviour with regard to: smoke gas In addition, Ensinger can offer the complete density, smoke gas toxicity, heat release documentation and traceability for all mate- ˌˌHigh specific strength due to fibre-rein- rials and manufacturing processes. The reli- forced plastics ability of these processes is documented ˌˌConvincing gliding properties with through all production procedures, such as outstanding dry-running characteristics compounding, semi-finished product extru- and freedom from maintenance in the sion and finished product production through application injection moulding or machining. ˌˌLow outgassing in vacuum ˌˌGood radiation resistance Ensinger is certified in accordance with ISO 9001:2008 and has a quality management system that follows international standards, implements them and anchors them permanently in procedures.

3 Plastics in application

Engineering and high-performance plastics used in aerospace engineering are required to comply with extremely stringent requirements.

Working in close cooperation with compa- Equipment and systems nies in the aviation industry, our specialists For materials used in the propulsion ele- have already developed a range of optimum ments, control units or landing gear, good solutions. electrical and thermal properties are essential. Controlled fire behaviour, low fume toxicity, Aircraft components good sliding properties and high chemical re- The airframe, aircraft fairing components, sistance are also a requirement. wings, nose, fuselage and tailplane are made of a number of components. The materials used for these must have good thermal and mechanical properties as well as good resistance to aging.

Cabin interior Because plastics are used in lighting systems, seats, the on-board kitchen and cooling systems, in the oxygen supply, drinking water and disposal systems, as well as freight loading facilities, in some cases supplementary specifications such as FDA, fungus test and drinking Material and parts water approvals are additionally required. Plastics used for such functions as fixing elements, ball bearings, seals or sliding bearings Propulsion systems have excellent mechanical properties. For applications in machines, components or housings, materials are required above all to offer good thermal resistance and sliding properties.

4 TECAFORM AH natural (POM-C)TECAFORM AD natural (POM-H) TECAFORM 66) 66 natural (PA TECAMID natural (PTFE) PTFE TECAFLON GF40 natural (PPS) TECATRON PVX black (PEEK)TECAPEEK GF30 natural (PEEK)TECAPEEK natural (PEEK)TECAPEEK natural (PAI) TECATOR (PI) TECASINT � � � � � � � � � � Aerostructure Door fairings e Fuselage and tailplane components e Wings: e e e Slats and fl aps, boxes, panels Airframe: Doors, components, electrics, pipes and leads, e e e e e cable ducts Components Fasteners e e e e Bearings e e e Sealings e e e e e Bushings e e e Refuelling and fuel systems e e e e e e e e Equipment, system & support Actuation & Control Systems: Air management, thermal and power management,

Aviation engine control, electrical landing system (ISR), sensors, e e e e e e e actuators and integration lighting, de-icing, fl ight control, door opening/closing control Landing Gear: Main and nose landing gear, steering system, extension/ e e e e e retraction system, kneeling system, wheels and brakes Cabin interior Seating, cabin lighting, galley, chilling systems, e e e e oxygen systems, drinking water systems, vacuum waste systems, cargo equipment Propulsion systems Engines and components: e e e e e e Propeller system, turbines Bearing bushes for engine guide vanes e Nacelles e e e

Satellites Antenna covers (radomes), e e e e e e e bearing bushes, sliding elements (vacuum) Construction and insulation components Wire coils, sealing rings e e e Space Radar cover e Torque cylinder e e e Fixing elements e e e Pipe holders e e e e e e

Key facts at a glance

Due to their beneficial material properties, technical plastics offer wide-ranging application possibilities for the aerospace industry.

5 Product portfolio The basis for wide-ranging applications

Over recent years, the significance of technical plastics has increased at an astounding speed. We offer a broad spectrum of engineering and high-performance materials from our standard product range for applications in the aerospace industry.

ˌˌTECAFINE (PE) ˌˌTECAFLON (PTFE, PVDF) ˌˌTECAFORM (POM) ˌˌTECASON (PSU, PPSU) ˌˌTECAPET (PET) ˌˌTECAPEEK (PEEK) ˌˌTECAMID (PA 6/66, PA 11/12) ˌˌTECATRON (PPS) ˌˌTECAST (PA 6 C) ˌˌTECATOR (PAI) ˌˌTECANAT (PC) ˌˌTECASINT (PI)

300 °C High-performance PI plastics PAI PEKEKK PEEK, PEK LCP, PPS PES PTFE, PFA 150 °C PPSU, PEI ETFE, PCTFE PSU, PPP PVDF Engineering plastics PC PA 46 100 °C PET, PBT PA 6-3-T PA 66 PA 6, PA 11, PA 12 POM PMP Long term service temperature Standard plastics PPE mod.

PMMA PP

PE PS, ABS, SAN

amorphous

Classification of plastics semi-crystalline

6 Special materials for aerospace technology

TECASINT 4121 / TECASINT 2021 (PI) TECASON P natural (PPSU) ˌˌLow friction and wear ˌˌHigh thermal dimensional stability ˌˌHDT / A up to 470 °C ˌˌHighly durable

TECASINT 4111 (PI) TECAPEI natural (PEI) ˌˌHigh stiffness, modulus 6.700 MPa ˌˌLong-term service temperature up to 170 °C ˌˌHeat distortion temperature ˌˌResistance to high-energy radiation HDT / A = 470 °C ˌˌLow outgassing in vacuum TECAFLON PTFE natural (PTFE) ˌˌExceptional chemical resistance TECASINT 2391 (PI) ˌˌParticularly low coefficient of friction

ˌˌModified with MoS2 ˌˌIdeally suited for soft mating partners ˌˌBest gliding properties in vacuum ˌˌLow outgassing in vacuum TECAMID 66 natural (PA 66) ˌˌEasily glued and welded TECASINT 2011 natural (PI) ˌˌElectrically insulating and good ˌˌMaximum strength and elongation machining properties ˌˌOptimum electrical insulation

ˌˌHighest modulus and minimal thermal TECAMID 66 MO black (PA 66 MoS2 ) conductivity ˌˌGood UV-resistance ˌˌLow abrasion TECAPEEK natural (PEEK) ˌˌHigh long-term service temperature (260 °C) TECAMID 66 GF35 natural (PA 66 GF) ˌˌExcellent mechanical properties even at ˌˌGlass-fibre reinforced high temperatures ˌˌHigh strength

PI TECAPEEK CF30 black (PEEK CF) TECAFORM AH natural (POM-C) PAI PEKEKK Very high strength value due to carbon Good chemical resistance PEEK, PEK ˌˌ ˌˌ LCP, PPS fibre reinforcement High resilience PES PTFE, PFA ˌˌ PPSU, PEI ETFE, PCTFE ˌˌVery abrasion-resistant PSU, PPP PVDF TECAFORM AH ELS (POM-C, conductive carbon) TECAPEEK GF30 natural (PEEK GF) ˌˌElectrically conductive PC PA 46 PET, PBT ˌˌGlass-fibre reinforced PA 6-3-T PA 66 PA 6, PA 11, PA 12 ˌˌIncreased strength TECAFORM AH SD (POM-C, antistatic) POM ˌˌOutstanding chemical resistance ˌˌStatic dissipating, carbon-free PMP ˌˌInherently effective, permanently PPE mod. TECAPEEK ELS nano (PEEK CNT) non-contaminating anti-static agent PMMA Electrically conductive PP ˌˌ ˌˌOutstanding chemical resistance TECAFORM AD natural (POM-H) PE PS, ABS, SAN ˌˌGood machinability ˌˌHigh mechanical strength

ˌˌVery good machining properties TECATRON GF40 natural (PPS GF) ˌˌExtremely high strength due to TECAFORM AD AF (POM-H TF) glass-fibre reinforcement ˌˌVery good slide friction properties ˌˌVery good chemical resistance ˌˌLow water absorption

7 Application examples

Wire coil for solar panel TECASINT 2391 black (PI) Low outgassing in accordance with ESA standard. High rigidity with low weight.

Sensor Plate (Component of aircraft air conditioning system) TECAPEEK GF30 natural (PEEK GF) High temperature resistance. Dimensionally stable.

8 Twin Pulley (Assembly for baggage-tray lift) TECAPEI GF30 natural mod. (PEI GF) High temperature resistance. Inherently flame-retardant. Very strong and rigid.

Output Pulley (Assembly for baggage-tray lift)TECAPEI GF30 natural mod. (PEI GF) High temperature resistance. Inherently flame-retardant. Very strong and rigid.

Attenuation Tube (Used in landing unit) TECAFORM AH white (POM-C) Dimensionally stable. Grease-resistant.

9 Mechanical properties

Continuous improvements in performance and fuel cost savings are crucial to success in the aerospace industry. This is why weight reduction and the optimization of mechanical aircraft component properties are key.

When selecting materials, specific strength is a key indicator. This deter- mines the tensile strength of a material relative to its density, and indicates the ratio of strength to weight. In order to assess the potential of thermoplastic or composite materials, this indicator is frequently used as the basis for comparison with low-weight, high-strength metals. In the aerospace industry, these are generally titanium or aluminium.

Specific strength [MPa / (g/cm³)]

0 20 40 60 80 100 120 TECAFORM AD AF natural

TECAFORM AD

TECAFORM AH SD natural

TECAFORM AH ELS black

TECAFORM AH

TECAMID 66 GF35

TECAMID 66 MO black

TECAMID 66

TECANAT

TECAFLON PFTE natural

TECAPEI

TECASON P white

TECATRON GF40

TECAPEEK ELS nano black

TECAPEEK CF30 black

TECAPEEK GF30

TECAPEEK

TECATOR 5013 natural

TECASINT 2011 natural

TECASINT 2021 black

TECASINT 2391 black

TECASINT 4111 natural

TECASINT 4121 black

Titanium*

AIMg3-alloy* *Source: Mechanical and Metal Trades Handbook

10 Creep strength Creep strength is the term given to the deformation increase depending on time and temperature under a constant load. TECASINT is a non-melting material which does not soften even under the influence of high temperatures and demonstrates very low creep tendency under load. The diagrams below demonstrate the creep strain depending on time and temperature under a load of 17 MPa.

Creep strain TECASINT at 250 °C 17 MPa, ISO 899-1 10

1 log creep[%] strain > 0,1 0,1 10 1000 > log time [h] TECASINT 2011 TECASINT TECASINT 4011 2011 TECASINT 4011 TECASINT 4111 TECASINT 4111

0,20,0 0,60,4 1,00,8 Creep Strain TECASINT at 150 °C 17 MPa, ISO 899-1 1 log reep strain [%] log reep strain > 0,1 0,1 10 1000 > log time [h] TECASINT 2011 TECASINT TECASINT 4011 2011 TECASINT 4011 TECASINT 4111 TECASINT 4111

11 Thermal properties

Glass transition temperature [°C] Melting temperature [°C]

–100- 0 100 200 300 400 °C An amorphous material can be subjected to TECAFORM AD natural mechanical wear above the Tg, as here its me- TECAFORM chanical strength decreases sharply. AH natural Partially crystalline materials, in contrast, still TECAMID 6 natural demonstrate a certain mechanical strength be- TECAMID 66 yond the T due to their crystalline areas, and natural g are therefore particularly well suited for com- TECAMID 66 black ponents exposed to mechanical stress. TECAMID 66 GF35 natural Melting temperature TECANAT natural The melting temperature Tm is the tempera- TECAFLON ture at which a material melts, i.e. changes PTFE natural from the solid to the fluid aggregate state and TECASON P natural its crystalline structures break down. TECAPEI natural TECATRON natural Service temperatures [°C] TECAPEEK –300- –200 –100 0 100 200 300 natural TECAFORM TECAPEEK AD natural CF30 black TECAFORM TECAPEEK AH natural GF30 natural TECATOR TECAMID 6 5013 TECAMID 66 TECASINT natural TECAMID 66 black Glass transition temperature [°C] TECAMID 66 Melting temperature [°C] GF35 natural TECANAT natural Glass transition temperature TECAFLON PTFE natural The glass transition temperature Tg is the temperature at which polymers change from TECASON P natural a hard elastic and brittle state to a flexible rub- TECAPEI bery elastic state. A distinction must be made natural here between amorphous and partially crystal- TECATRON natural line thermoplastics. TECAPEEK natural T T g TECAPEEK g CF30 black TECAPEEK Tm GF30 natural TECATOR 5013

• Modulus • Modulus TECASINT • Temperature • Temperature

amorphous semi-crystalline Negative application temperature • • Service temperature long-term long-term short-term short-term

12 Long-term service temperature Coefficient of linear thermal expansion The long-term service temperature is defined The coefficient of linear thermal expansion as the maximum temperature at which a plas- specifies the extent of a change in the length tic has lost no more than 50 % of its initial of a material due to rising or falling tempera- properties after 20,000 hours of storage in hot ture. Due to their chemical structure, plastics air (in accordance with IEC 216). generally demonstrate a significantly higher coefficient of linear thermal expansion than The maximum service temperature is depend- metals. This must be considered in the event ent upon the following factors: of: ˌˌDuration of exposure to temperature ˌˌComponents with narrow tolerances ˌˌMaximum admissible deformation ˌˌHigh temperature fluctuations ˌˌDegradation of strength characteristics due ˌˌComposites with metal to thermal oxidation ˌˌAmbient conditions The coefficient of linear thermal expansion of plastics can be significantly reduced by adding Negative service temperatures reinforcing fibres. In this way, values in the The service temperature in the negative tem- range of aluminium can be achieved. perature range is not precisely defined and depends largely on different characteristics and Coefficient of linear thermal expansion, longitudinal ambient conditions: CLTE [10-5 1/K] ˌˌToughness / brittleness of a material 0 2 4 6 8 10 12 14 ˌˌModifications, i.e. reinforcement fibres TECAFORM ˌˌTemperature AD natural ˌˌDuration of load TECAFORM ˌˌType of load AH natural TECAMID 6 natural Short-term service temperature TECAMID 66 The short-term service temperature is the natural short-term peak temperature which the plastic TECAMID 66 can tolerate over a short period (from minutes black TECAMID 66 to occasionally hours) taking into considera- GF35 natural tion the stress level and duration, without sus- TECANAT taining damage. natural TECAFLON PTFE natural TECASON P MT coloured TECAPEI natural TECATRON natural TECAPEEK natural TECAPEEK CF30 black TECAPEEK GF30 natural

CLTE [23 – 60 °C] CLTE [23 – 100 °C] CLTE [100 – 150 °C]

13 Electrical properties

Surface resistance Comparative tracking index The specific surface resistance describes the To determine a material’s insulating capac- resistance that a material exerts against the ity, the comparative tracking index (CTI) is flow of electricity at the surface: 1 Ω = 1 V/A frequently used. This provides a statement on For measurement, a standardized set-up must the insulation resistance of the surface (creep be used, as the specific surface resistance de- distance) of insulating materials. Even in the pends on different factors: case of good insulating plastics, however, hu- ˌˌMaterial midity and contamination on the surface (even ˌˌHumidity temporarily) can result in failure of a compo- ˌˌSurface contamination nent. ˌˌMeasurement set-up The comparative tracking index can be heavily It is also impossible to prevent volume resis- influenced by combination with material addi- tivity from entering the equation to an inde- tives, in particular colour pigments. terminable degree when measuring surface resistance. Comparative tracking index [V]

0 100 200 300 400 500 600 Specific volume resistivity TECAFORM AD natural The specific volume resistivity describes the TECAFORM electrical resistance of a homogeneous material AH natural to the flow of current through the specimen. TECAFORM As the volume resistivity of many materials fol- AH SD natural lows Ohm‘s law, it is independent of the applied TECAMID 66 GF30 natural voltage and can be specified proportionally to TECAMID 66 the length or conversely proportionally to the MO black cross-section of the measured specimen. The TECAPEI* unit of specific volume resistivity is consequent- natural TECATRON ly Ω cm. GF40 natural TECAPEEK Dielectric strength natural Dielectric strength is the resistance of insu- TECAPEEK GF30* natural lating materials to high voltage. The charac- * Published values teristic value is the quotient of the voltage level and the test specimen thickness (unit of measurement kV/mm). Dielectric strength is Conductivity ranges surface resistance [Ω] particularly decisive with thin-walled compo- Standard SD ELS Metal nents. plastic antistatic insulating static conductive conductive conducting Dissipation factor

A high dissipation factor causes the genera- 1016 1014 1012 1010 108 106 104 102 100 10-2 10-4 tion of heat in the plastic part, which acts as a dielectric. The dissipation factor of plastic Plastics without TECAFORM TECAFORM AH ELS black carbon fibres AH SD TECAPEEK ELS nano black insulators in high-frequency applications such or conductivity natural as radar devices, antenna applications and mi- additives crowave parts should consequently be as low Carbon fibre-filled plastics as possible. The dissipation factor depends on moisture content, temperature, frequency and voltage.

14 Radiation resistance

Radiation resistance Ionizing radiation Depending on their field of application, plas- Ionizing radiation such as gamma and X-rays tics can come into contact with different types are frequently found in medical diagnostics, of radiation, which under certain circumstanc- radiation therapy, in the sterilization of dispos- es can permanently influence the structure of able articles and also in the testing of materials the plastics. The spectrum of electromagnetic and in test instrumentation, as well as in ra- waves ranges from radio waves with a large dioactive and other radiant environments. The wavelength, through normal daylight with its high energy radiation in these applications short-wave UV radiation, to extremely short- often leads to a decrease in the elongation wave X and gamma rays. The shorter the characteristics and the development of brit- wavelength of the radiation, the greater the tleness. The overall service life of the plastic susceptibility of a plastic to damage. is dependent upon the total amount of radiation absorbed. PEEK, PI and the amorphous Electromagnetic radiation sulphur-containing polymers, for example, are The dissipation factor describes the proportion proved to have very good resistance towards of energy which can be absorbed by the plas- gamma radiation and X-rays. tic. Plastics with high dissipation factors heat The influence of high-energy radiation results up considerably in alternating electrical fields in a change to the mechanical characteristics and are consequently not suitable for use as (strength, rigidity, hardness or brittleness). a material for high-frequency and microwave This influence on the mechanical characteris- insulating applications. Polyamides, for exam- tics is reinforced under the influence of the ra- ple, can fracture or explode when used for a diation dose. Consequently no sudden return microwave application due to their high mois- to the prior state takes place. ture absorption. Information relating to the resistance of plastics should only ever be considered a point of Ultraviolet radiation reference, as different parameters play a co- UV radiation from sunlight is decisive in un- determining role (for instance part geometry, protected open-air applications. Plastics which dosing rate, mechanical stress, temperature are inherently resistant are to be found in the or ambient medium). For this reason, it is group of fluorinated polymers, for example impossible to provide a generalized statement PTFE and PVDF. Without suitable protective of the different damaging radiation doses for measures, various other plastics begin to yel- individual plastics. low and become brittle depending upon the level of irradiation. UV protection is usually Radiation resistance [kGy] achieved using additives or protective surface 0 500 1000 1500 coatings. The addition of carbon black is a low- TECAFORM AH cost and very effective way of stabilizing many TECAMID plastics. 6 / 66

TECANAT

TECAFLON PTFE

TECATRON

TECAPEEK 20000

TECASINT 40000

Radiation dose in Kilogray [kGy] which reduces elongation by less than 25 %.

15 Combustibility

With regard to flame retardant classification, a variety of characteristics are of relevance. Requirements imposed on material behaviour are listed in the specifications in the form of fire protection properties.

Combustibility testing to UL94 is generally Smoke gas density of plastics performed on raw material. Alongside testing Specific optical density (Dg) in accordance with the specifications of UL or using a UL-accredited laboratory, listing (us- 0 100 200 400 500 600 700 800 ing so-called yellow cards) is also performed PVC directly by UL itself. For this reason, a distinc- PS tion must be made between materials with a TECARAN UL listing and materials which only comply (ABS) with the requirements of the respective UL TECAPET classification (without listing). (PET) TECANAT (PC) Alongside flame retardant classification in TECADUR accordance with UL94, a wide range of other (PSU) industry-specific tests exists which classify TECAPEI the combustion behaviour of plastics. The (PEI) FAR 25.853 is a typical fire test specification TECAFLON PTFE (PTFE) for aerospace applications. In addition to pure TECAPEEK combustibility using the vertical test, it also (PEEK) contains tests to determine smoke density and Test conditions: Smoke chamber of the American National toxicity under the influence of radiant heat and Bureau of Standards, sample 3.2 mm thick, flaming mode flames. Source: Victrex plc.

Behaviour under minimal fire load, smoke and toxicity Outgassing TECAPEEK materials from Ensinger perform Tests in compliance with the ESA regula- well when subjected to fire due to being in- tion indicate no condensable impurities in herently flame retardant. When compared to TECASINT. The products listed in the follow- other plastic materials, TECAPEEK has the ing table can consequently be used in high lowest value of specific optical density of all the vacuum / space applications: materials tested. Low outgassing according to ESA regulations ECSS-Q-70-02 Pure 1011 2011 3011 4011 4111

15 % MoS2 1391 2391 4391

30 % MoS2 1041 4041

16 Chemical resistance

Temperature, the concentration of agents, ex- intended to provide any legally binding assur- posure periods and also mechanical load are ance or guarantee of the chemical resistance of all important criteria when testing for chemical our products or their suitability for a concrete resistance. The following table lists resistance application. For a more concrete application, to different chemicals. This information is pro- we recommend producing your own verifica- vided to the best of our current knowledge and tion. Standard tests are performed under nor- is designed to provide data about our products mal climatic conditions 23/50 in accordance and their applications. Consequently it is not with DIN 50 014. [°C]emperature Concentration [ %] Concentration T TECASINT (PI) TECAPEEK (PEEK) (PPS) TECATRON TECASON S (PSU) TECASON E (PES) TECASON P white (PPSU) TECAPEI (PEI) (PTFE) PTFE natural TECAFLON (PCTFE) PCTFE natural TECAFLON (PVDF) PVDF natural TECAFLON 6 C) 6 C), TECARIM (PA 6), TECAST (PA TECAMID 6 (PA 66) 46, PA TECAMID 46, 66 (PA 12) 11, PA TECAMID 11, 12 (PA (PC) TECANAT TECAPET (PET), (PBT) natural TECADUR PBT AH (POM-C)TECAFORM AD (POM-H) TECAFORM (PP) TECAFINE PP (PP), TECAPRO TECAFINE (PE) PE natural TECARAN ABS (ABS) TECANYL (PPE)

Acetonitrile C2H3N UD RT + - + +

Dichloromethane CH2Cl2 UD RT + + (+) - - - + (+) + (+) (+) (+) - - (+) (+) - (+) - - De-icing fluid CA RT + Aircraft fuel A CA RT + Aircraft fuel A CA 40 + Aircraft fuel A/A-1 CA RT + Hydraulic fluid UD RT + Kerosene CA RT + + + + + + + + + (+) + + + + Kerosene CA 60 + + + + + + + + + + + + (+) Kerosene CA 85 + (+) + + + + + + - + +

Methanol CH4O CA 100 + Sodium hydroxide NaOH 50 RT + (+) (+) (+) - (+)

Nitric acid HNO3 10 80 + - + (+) + + ------Hydrochloric acid HCl(aq) 20 100 + + + + ------

Sulphuric acid H2SO4 20 RT (+) + + + + + + - - - + + - + Skydrol® LD-4* CA RT + Skydrol® LD-4* CA 85 + Skydrol® 500B* CA RT + Skydrol® 500B* CA 100 + Skydrol® 500B* CA boiling + Xylene CA 125 +

+ = resistant (+) = limited resistance - = not resistant RT = Room temperature (15 - 25 °C) UD = Undiluted CA = Commercially available

* Skydrol is a registered trademark of Solutia Inc.

A comprehensive overview of the chemical resistance of our products is provided at www.ensinger-online.com

17 Influence of processing on test results

The macroscopic characteristics of thermoplas- The thermal prior history of a thermoplastic tics depend heavily on the relevant processing also exerts a considerable influence on the method used. Because of the higher shear ra- relevant characteristic values. The cooling pro- tes typical of the processing method, injection cess of injection moulded components tends moulded components demonstrate a far more to be faster than for extruded semi-finished pronounced orientation of macromolecules and products. Consequently there is a noticeable any additives in the filling direction than, for in- difference in the degree of crystallinity, par- stance, semi-finished extruded products which ticularly in the partially crystalline plastics. are exposed to rather lower shear rates. Special additives with a high aspect ratio (such as glass In the same way as processing methods, the or carbon fibres) end to align themselves predo- shapes of semi-finished products (rods, plates, minantly in the direction of flow at higher shear tubes) and their different dimensions (diam- rates. The anisotropy which occurs as a result eter and thickness) also exert an influence on brings about higher strengths in tensile testing, the macroscopic properties and determined as here the direction of flow corresponds to the characteristic values. direction of testing. The table below provides a schematic overview of the influence exerted by the different processing methods on typical characteristics. Test specimen made of an extruded and machined semi-finished product Chaotic alignment of fibres and macromolecules To allow a comparison of the different test results in this context, DIN EN 15 860 “Thermoplastic semi-finished products” stipu- Injection moulded test specimen Alignment of fibres and macromolecules in the lates that test specimens must be taken from d/4 d/4 direction of testing (parallel to the direction of flow) rods with a diameter of 40 w– 60 mm as follows: w s t d/4 d/4 Test specimen

d/4 d/4 w w d Diameter s t s Thickness d/4 d/4 w Width d d

d d

Tendential influence of processing on characteristic values

unreinforced fibre-reinforced thermoplastics thermoplastics

Injection Injection Extrusion Extrusion Moulding Moulding

Tensile strength • • • •

Modulus of elasticity • • • •

Tensile elongation at break • • • •

18 Frequently asked questions

What is the meaning of risk classification Which statutory regulations are we required to to Class I, II or III, and what impact does this adhere to? have? Only the contractual rulings between the man- Generally speaking, the classification impacts ufacturing company and supplier have to be on the processes used for component approval. adhered to for aviation-specific applications. This is set out in the Basic Regulation 216/2008 More information on this is provided in this under CS – 25; which has been adopted from brochure under Quality Management / Rules the FAA. The POA holder (manufacturing and Regulations. company) is responsible for component classification. Here, classification and the necessary Does a duty to notify exist on the part of the agreements / notifications must take place at customer in the event of statutory changes? the Aviation Agency. Statutory regulations only apply to aviation-approved corporations. All other points have to be Do regulations exist for semi-finished part and regulated in supply agreements. Consequently, component suppliers? the customer is required to inform its supplier Statutory regulations only apply to aviation ap- of a change to the requirements by amending proved corporations. Requirements imposed the supply agreements. There is no explicit on subcontractors are generally regulated by duty of notification on the part of the customer. means of contractual agreements. However, where applicable, the customer is required to adjust its specifications / supply What is the difference between the FAA and agreements with the supplier. the EASA? As a result of bilateral agreements, the two Where can I find the relevant information? organizations are virtually identical. The The European Aviation Safety Agency and American FAA regulation is considered to be the Society of Aerospace Engineers offer ad- the global leader. ditional useful information on their websites: For more information on the European Avia- tion Safety Agency, go to: www.easa.europa.eu/

European Aviation Society of Aerospace Safety Agency Engineers

Key facts at a glance

Please do not hesitate to contact our technical service: [email protected] or by telephone on +49 7032 819 101

19 Quality management

Rules and regulations In the field of civil aviation, manufacturing In addition, there is an increasing demand for corporations approved by the German Aviation international standards. The most common Agency (LBA) exist. These are known as POA international standards are: holders. They are approved as manufacturing ˌˌASTM (USA): American standard companies and are subject to the rules and encompassing test methods and so-called regulations of the German Aviation Agency, material codes which characterize the which apply directly to these companies. No properties of the raw material. aviation-specific statutory regulations exist for ˌˌASTM D-6778 (POM) the field of semi-finished plastic parts which ˌˌASTM D-4066 (PA 6 and PA 66) are directly applicable to subcontractors of cor- ˌˌASTM D-3965 (PC) porations with aviation approval. It lies within ˌˌMil Spec (Military Specification / USA): the sphere of responsibility of the manufactur- encompasses American test methods ing company to ensure the consistent quality in accordance with the ASTM described of its suppliers. above. ˌˌFor example: MIL P-46183 (PEEK) Comparable regulations exist in the USA. ˌˌLP (USA – Federal Specification) Here, the government agency (FAA) draws ˌˌFor example: L-P-410a for polyamides. up the rules and regulations which must be adhered to by the aircraft manufacturers. Confirmation of these standards must be clari- The manufacturers in turn implement these fied in each individual case with Ensinger, as requirements in the form of specifications it may happen that special raw materials have which have to be adhered to by the suppliers. to be used.

Standards Specifications Manufacturing corporations can draw on a If the specifications in the standards do not series of national and international standards comply with the manufacturer’s require- which they can apply in cooperation with sup- ments, these are frequently supplemented by pliers. additional individual specifications. In Germany and Europe, the main following standards apply: Because our customer base includes the big- gest manufacturers operating in the aerospace ˌˌMaterial Data Sheets (for instance WL industry, we are familiar with the customary 5.2206.3) list the physical properties of procedures and processes for product qualifi- the materials. In most cases, properties cation and order processing in this sector. of injection moulded test bodies are used as a basis. However, these are not directly As a manufacturer of semi-finished products, comparable with values at the semi-finished Ensinger is responsible for and capable of product. complying with the required specifications. ˌˌAviation Standards (for example LN 9388) The company’s organization, starting with an describe the dimensions and tolerances for in-house sales team specializing in aviation, semi-finished products and are comparable through to an efficient compliance manage- with the semi-finished products standard ment department, ensures that individual cus- (DIN 15860). tomer requirements are taken into account.

20 Traceability

Due to product coding and statements of conformity, Ensinger has direct traceability of the delivered semi finished product.

Ensing er GmbH Postfach 11 61 D-71150 Nufringen Ensinger GmbH Lieferschein - intern - Liefertermin 30.01.2012 Rudolf-Diesel-Str. 8 Bitte b Blatt 1 / 1 71154 Nufringen ei Zahlung und Rückfragen angeben Kunde Auftrag Lieferschein Datum 999999 242505 452992 30.01.2012 Achtung Testfirma 999 !!! Ihr Ansprechpartner: Yüce, Ismail Ihre Ust-Id-Nr: Telefonnummer: +49 07032-819 149 Ihre Zeichen: Faxnummer: Ihre Bestellung vom: ENSINGER Musterfirma +49 07032-819 432 30.01.2012 Ihre Auftr. Nr.: 123456 Rechnungsaddresse: Ensinger GmbH - intern - 01.06.2012 Rudolf-Diesel-Str. 8 71154 Nufringen DEUTSCHLAND INTERN 123456 78910 111213 01.06.2012 Pos. Lfnr Bestellmenge BE Gegenstand / Abmessung Frau Maja Muster Liefermenge/kg 01.05.2012 Liefermenge LE Frau Mustermann 5 Offene Menge 5,00 m RUNDSTAB 32 MM 1234/12/12/XY ++49 01234-5678 10 "Kunststoffe TECA ++49 01234-5678 11 PEEK MT (PEEK eingefärbt) sind 5,00 m Customer · Order · Invoice nicht für die Verwendung als medizintechnische 1 Invoice / delivery note Implantate geei gnet." TECAPEEK MT sw ENSINGER Musterfirma Lieferlänge: 1.000 mm

Frachtführer ohne ausreichende Si cherungsmittel Wir haften nicht für daraus enstehende Verspätungsschäden. zur Ladungssicherung werden nicht beladen. Lieferbedingung: Spediteur: Frei Haus, einschließlich Verpackung The order and invoice number is shown on the invoice / 988885 · 123456 · DRA12345 GLS delivery note, for semi-finished products the batch num-

Wir liefern Ihnen gemä ß unseren allgemeinen V Hausanschrift erkaufs- und Lieferbedingung en (download: www.ensinger -online.com) unter a Rudolf-Diesel-Str. 8 Banken usdrücklichem Ausschluss entgegenstehen D-71154 Nufringen BLZ Kont der Einkaufsbedingungen. o Swi ft-Code ENSIN Tel. +49-(0)7032-819-0, Fax -100 LBBW Stuttg art GER Gmb 600 501 01 8 806 0 55 SOLADEST Registergericht Stuttgart, HRBH 241486 Production number 248086 Internet: http://www.en ber is also shown on the delivery note. This allows goods sin eMail: [email protected] Deutsche Bank Stuttgart 600 700 70 0 580IBAN: 019 DEUTDESS DE Finanzamt Böblingen 56455/00772 62 6005 0101 0008 8060 55 Geschäftsführer: Klaus

Ensinger; Dr. R IBAN: DE13 6007 0070 0058 0019 USt.-IdNr.: DE 145163194 oland Reber to be traced back using these numbers. A certificate to ISO 10204 is issued on an order-specific basis.

2 Semi-finished products The production and manufacturing number is located on the semi-finished product. Starting with the production or manufacturing number data from the production pro- cess can be traced (production data, production protocol, Production number control cards).

3 Compound The lot number of the compound can be determined from the production / manufacturing number of the semi-finished product.

4 Raw materials The lot number of the compound is traceable back to the formulation and so to the delivered raw material batch, the relevant raw material specification and the safety data sheet.

21 Material standard values

Material TECASINT TECASINT TECASINT TECASINT TECAPEEK TECAPEEK TECAPEEK TECAPEEK TECATEC TECATRON 4111 4121 2391 2011 natural GF30 CF30 ELS nano PEEK MT GF40 natural black black natural natural black black CW50 natural black Polymer PI PI PI PI PEEK PEEK PEEK PEEK PEEK PPS

Fillers 15 % 15 % MoS2 glass carbon CNT glass graphite fibres fibres fibres

Density [ g / cm³ ] 1.46 1.53 1.54 1.38 1.31 1.53 1.38 1.36 1.49 1.63 (DIN EN ISO 1183) Mechanical properties

Modulus of elasticity (tensile test) [ MPa ] 6,700 6,600 4,400 3,700 4,200 6,400 6,800 4,800 53,200 6,500 (DIN EN ISO 527-2) Tensile strength [ MPa ] 100 34 95 118 116 105 122 106 491 83 (DIN EN ISO 527-2) Tensile strength at yield [ MPa ] 116 105 122 106 83 (DIN EN ISO 527-2) Elongation at yield [ % ] 5 3 7 4 3 (DIN EN ISO 527-2) Elongation at break [ % ] 1.7 0.5 2.9 4.5 15 3 7 4 3 (DIN EN ISO 527-2) Modulus of elasticity (flexural test) [ MPa ] 6,100 6,100 4,136 3,600 4,200 6,600 6,800 4,700 48,900 6,600 (DIN EN ISO 178) Flexural strength [ MPa ] 160 113 137 177 175 164 193 178 813 145 (DIN EN ISO 178) Compression modulus [ MPa ] 2,500 2,200 2,200 1,713 3,400 4,800 5,000 3,600 4,050 4,600 (EN ISO 604) Compressive strength (1 % / 2 %) [ MPa ] 23 / 43 29 / 52 25 / 47 27 / 47 21 / 41 (EN ISO 604) Impact strength (Charpy) [ kJ / m² ] 24 11 87.9 n.b. 33 62 58 24 (DIN EN ISO 179-1eU) Notched impact strength (Charpy) [ kJ / m² ] 1.1 1.4 9.3 4 (DIN EN ISO 179-1eA) Ball intendation hardness [ MPa ] 345 265 260 253 316 355 253 333 (ISO 2039-1) Thermal properties

Glass transition temperature [ °C ] n.a. n.a. 370 370 150 147 147 147 143 93 (DIN 53765) Melting temperature [ °C ] n.a. 341 341 341 341 343 280 (DIN 53765) Service temperature, [ °C ] 270 300 300 300 300 260 short term Service temperature, [ °C ] 250 260 260 260 260 260 230 long term Thermal expansion (CLTE), [ 10-5 K-1 ] 5 4 4 5 4 23 – 60 °C (DIN EN ISO 11359-1;2) Thermal expansion (CLTE), [ 10-5 K-1 ] 3 4 4 5 4 4 5 5 23 – 100 °C (DIN EN ISO 11359-1;2) Specific heat [ J / ( g � K ) ] 0.925 1.1 1.0 1.2 1.1 1.0 (ISO 22007-4:2008) Thermal conductivity [ W / ( m � K ) ] 0.35 (b) 0.22 (b) 0.27 0.35 0.66 0.46 0.35 (ISO 22007-4:2008) Electrical properties

Specific surface resistance [ Ω ] 1016 (c) 1015 1015 1014 > 108 (e) 102 – 104 (e) 1014 (DIN IEC 60093) Specific volume resistance [ Ω � cm ] 1016 (c) 1015 1015 1014 103 – 1011 (e) 103 – 105 (e) 1014 (DIN IEC 60093) Dielectric strength [kV/mm] 73 36 (DIN EN 60243-1) Resistance to tracking (CTI) [V] 125 (DIN EN 60112) Miscellaneous data

Water absorption 24 h / 96 h (23 °C) [ % ] 0.01 / 0.02 0.12 / 0.24 0.14 / 0.30 0.02 / 0.03 0.02 / 0.03 0.02 / 0.03 0.02 / 0.03 < 0.01 / 0.01 (DIN EN ISO 62) Resistance - + + + + + + to hot water / bases Resistance to weathering - - - (+) - -

Flammability (UL94) V0 (d) V0 (d) V0 (d) V0 (d) V0 V0 (d) V0 (d) V0 (d) V0 (d) V0 (d) (DIN IEC 60695-11-10)

Data generated directly after machining (standard + good resistance (a) Thermal conductivity testing according to ASTM C 177 climate Germany). For polyamides the values strongly (+) limited resistance (b) Thermal conductivity testing according to ISO 8302 depend on the humidity content. – poor resistance (depending on concen- (c) Specific surface resistance and volume resistance tration, time and temperature) to ASTM D 257 n.b. not broken (d) No listing at UL (yellow card) n.a. not applicable (e) Specific surface resistance and volume resistance testing according to DIN EN 61340-2-3 (f) Dielectric strength testing according to ASTM D 149 Test specimen to DIN EN ISO 527-2 (g) Tensile test according to ASTM D 4894

22 Material TECASON TECAPEI TECAFLON TECANAT TECAMID TECAMID TECAMID TECAFORM TECAFORM TECAFORM P natural PTFE natural 66 66 MO 66 GF35 AH AH ELS AD white natural natural black natural natural black natural

Polymer PPSU PEI PTFE PC PA 66 PA 66 PA 66 POM-C POM-C POM-H

Fillers MoS2 glass conductive fibres carbon black Density [ g / cm³ ] 1.31 1.28 2.15 1.19 1.15 1.15 1.41 1.41 1.41 1.43 (DIN EN ISO 1183) Mechanical properties

Modulus of elasticity (tensile test) [ MPa ] 2,300 3,200 2,200 3,500 3,200 5,600 2,800 1,800 3,400 (DIN EN ISO 527-2) Tensile strength [ MPa ] 81 127 22 (g) 69 85 84 98 67 42 79 (DIN EN ISO 527-2) Tensile strength at yield [ MPa ] 81 127 69 84 83 67 42 79 (DIN EN ISO 527-2) Elongation at yield [ % ] 7 7 6 7 10 6 9 11 37 (DIN EN ISO 527-2) Elongation at break [ % ] 50 35 220 (g) 90 70 40 9 32 11 45 (DIN EN ISO 527-2) Modulus of elasticity (flexural test) [ MPa ] 2,300 3,300 2,300 3,100 3,100 2,600 1,500 3,600 (DIN EN ISO 178) Flexural strength [ MPa ] 107 164 97 110 114 91 56 106 (DIN EN ISO 178) Compression modulus [ MPa ] 2,000 2,800 2,000 2,700 2,700 2,300 1,500 2,700 (EN ISO 604) Compressive strength (1 % / 2 %) [ MPa ] 18 / 30 23 / 41 16 / 29 20 / 35 20 / 38 20 / 35 16 / 25 19 / 33 (EN ISO 604) Impact strength (Charpy) [ kJ / m² ] n.b. 113 n.b. n.b. n.b. n.b. 74 n.b. (DIN EN ISO 179-1eU) Notched impact strength (Charpy) [ kJ / m² ] 13 14 5 5 8 15 (DIN EN ISO 179-1eA) Ball intendation hardness [ MPa ] 143 225 128 175 168 165 96 185 (ISO 2039-1) Thermal properties

Glass transition temperature [ °C ] 218 216 20 149 47 52 48 -60 -60 -60 (DIN 53765) Melting temperature [ °C ] n.a. n.a. n.a. 258 253 257 166 169 182 (DIN 53765) Service temperature, [ °C ] 190 200 260 140 170 170 170 140 140 150 short term Service temperature, [ °C ] 170 170 260 120 100 100 110 100 100 110 long term Thermal expansion (CLTE), [ 10-5 K-1 ] 6 5 8 11 10 13 13 12 23 – 60 °C (DIN EN ISO 11359-1;2) Thermal expansion (CLTE), [ 10-5 K-1 ] 6 5 8 12 10 14 14 13 23 – 100 °C (DIN EN ISO 11359-1;2) Specific heat [ J / ( g � K ) ] 1.1 1.2 1.3 1.5 1.5 1.4 1.3 1.3 (ISO 22007-4:2008) Thermal conductivity [ W / ( m � K ) ] 0.25 0.21 0.20 (a) 0.25 0.36 0.36 0.39 0.46 0.43 (ISO 22007-4:2008) Electrical properties

Specific surface resistance [ Ω ] 1014 1014 1016 (c) 1014 1014 1014 1014 1014 102 – 104 (e) 1014 (DIN IEC 60093) Specific volume resistance [ Ω � cm ] 1014 1017 (c) 1014 1014 1014 1014 1013 103 – 105 (e) (DIN IEC 60093) Dielectric strength [kV/mm] 80 (f) 35 49 (DIN EN 60243-1) Resistance to tracking (CTI) [V] 600 600 (DIN EN 60112) Miscellaneous data

Water absorption 24 h / 96 h (23 °C) [ % ] 0.1 / 0.2 0.05 / 0.1 0.03 / 0.06 0.2 / 0.4 0.2 / 0.4 0.05 / 0.1 0.05 / 0.2 0.05 / 0.1 (DIN EN ISO 62) Resistance + + - (+) (+) (+) (+) (+) - to hot water / bases Resistance to weathering - - (+) - (+) (+) - (+) -

Flammability (UL94) V0 (d) V0 (d) V0 (d) HB (d) HB (d) HB (d) HB (d) HB (d) HB (d) HB (d) (DIN IEC 60695-11-10)

The corresponding values and information are no minimum determined by tests at reference dimensions (typically rods Data sheet values are subject to periodic review, the most or maximum values, but guideline values that can be used with diameter 40-60 mm according to DIN EN 15860) on recent update can be found at www.ensinger-online.com primarily for comparison purposes for material selection. extruded, cast, compression moulded and machined speci- These values are within the normal tolerance range of mens. As the properties depend on the dimensions of the product properties and do not represent guaranteed property semi-finished products and the orientation in the component values. Therefore they shall not be used for specification (esp. in reinforced grades), the material may not be used purposes. Unless otherwise noted, these values were without separate testing under individual circumstances. Technical changes reserved.

23 Ensinger Germany Ensinger worldwide

Ensinger GmbH Austria Germany Singapore Rudolf-Diesel-Str. 8 Ensinger Sintimid GmbH Ensinger GmbH Ensinger Asia Holding Pte Ltd. 71154 Nufringen Werkstr. 3 Rudolf-Diesel-Straße 8 63 Hillview Avenue # 04-07 Tel. +49 7032 819 0 4860 Lenzing 71154 Nufringen Lam Soon Industrial Building Fax +49 7032 819 100 Tel. +43 7672 7012800 Tel. +49 7032 819 0 Singapore 669569 www.ensinger-online.com www.ensinger-sintimid.at www.ensinger-online.com Tel. +65 65524177 www.ensinger.com.sg Ensinger GmbH Brazil India Mercedesstr. 21 Ensinger Indústria de Ensinger India Engineering Spain 72108 Rottenburg a. N. Plásticos Técnicos Ltda. Plastics Private Ltd. Ensinger S.A. Tel. +49 7457 9467 100 Av. São Borja 3185 R.K Plaza, Survey No. 206/3 Girona, 21-27 www.ensinger-online.com 93.032-000 São Leopoldo-RS Plot No. 17, Lohgaon, 08120 La Llagosta Tel. +55 51 35798800 Viman Nagar Barcelona Ensinger GmbH www.ensinger.com.br 411 014 Pune Tel. +34 93 5745726 Wilfried-Ensinger-Str. 1 Tel. +91 20 2674 1033 www.ensinger.es 93413 Cham China www.ensinger.in Tel. +49 9971 396 0 Ensinger (China) Co., Ltd. Sweden www.ensinger-online.com 1F, Building A3 Italy Ensinger Sweden AB No. 1528 Gumei Road Ensinger Italia S.r.l. Stenvretsgatan 5 Ensinger GmbH Shanghai 200233 Via Franco Tosi 1/3 SE-749 40 Enköping Borsigstr. 7 Tel. +86 21 52285111 20020 Olcella di Tel. +46 171 477 050 59609 Anröchte www.ensinger-china.com Busto Garolfo (MI) www.ensinger.se Tel. +49 2947 9722 0 Tel. +39 0331 562111 www.ensinger-online.com Czech Republic www.ensinger.it Taiwan Ensinger s.r.o. Ensinger Asia Holding Pte Ltd. Ensinger GmbH Prùmyslová 991 Japan 1F, No.28, Keda 1st Rd. Mooswiesen 13 P.O. Box 15 Ensinger Japan Co., Ltd. Zhubei City 88214 Ravensburg 33441 Dobřany 3-5-1, Rinkaicho, Hsinchu County 302 Tel. +49 751 35452 0 Tel. +420 37 7972056 Edogawa-ku, Tokyo Tel. +886 3 6570185 www.thermix.de www.ensinger.cz 134-0086, Japan www.ensinger.asia/tw Tel. +81 3 5878 1903 Denmark www.ensinger.jp United Kingdom Ensinger Danmark A/S Ensinger Limited Rugvænget 6B Poland Wilfried Way 4100 Ringsted Ensinger Polska Sp. z o.o. Tonyrefail Tel. +45 7810 4410 ul. Geodetów 2 Mid Glamorgan CF39 8JQ www.ensinger.dk 64-100 Leszno Tel. +44 1443 678400 Tel. +48 65 5295810 www.ensinger.co.uk France www.ensinger.pl Ensinger France S.A.R.L. USA ZAC les Batterses Ensinger Inc. ZI Nord 365 Meadowlands Boulevard 01700 Beynost Washington, PA 15301 Tel. +33 4 78554574 Tel. +1 724 746 6050 www.ensinger.fr www.ensinger-inc.com

Thermoplastic engineering and high-performance plastics from Ensinger are used in every important sector of industry today. Their economy and performance benefits have seen them frequently supplant classically used materials. E9911075A022GB 10/14