KetaSpire ® KetaSpire® PEEK Design & Processing Guide SPECIALTY POLYMERS Table of Contents Introduction and Typical Properties . .5 Long-Term Mechanical Properties . 30 Solvay Gives You More Choices for Creep Properties . 30 Performance and Value . 5 Isochronous Curves . 30 KetaSpire® PEEK key properties . 5 Apparent or Creep Modulus Graphs . 31 KetaSpire® PEEK Grades . 5 Fatigue Properties . 33 Design Considerations . 33 Property Data . 6. Fatigue Testing . 33 Testing KetaSpire® PEEK . 34 Agency Approvals . .14 Tensile Fatigue of Neat PEEK Resins . 34 Food Contact . 14 Tensile Fatigue of Carbon-Fiber Reinforced ISO 10993 . 14 KetaSpire® PEEK . 34 National Sanitation Foundation . 14 Tensile Fatigue of Glass-Fiber Reinforced International Water Contact Standards . 14. KetaSpire® PEEK at 160 °C (320 °F) . 34 Underwriters Laboratories . 14 ASTM International . 14 Temperature Effects . 35 US Military Specifications . 14 Thermal Properties . 35 Short-Term Mechanical Properties . 15. Linear Thermal Expansion . 35 Definition . 35 Poisson’s Ratio . 15 Measurement . .35 CLTE results . 37 Tensile Properties . 15 Design implications . 37 Effect of Fibrous Reinforcement . 17 Comparing CLTE values from different sources . .37 Effect of Molecular Weight . 18 Deflection Temperature Under Load (HDT) . 38 Effect of Temperature . 18 Glass Transition Temperature (T ) . 39 Stress-strain curves . 19 g Melting Temperature (Tm) . 39 Flexural Properties . 23 Thermal Conductivity . 39 Test Methods . 23 Specific Heat . 40 Effect of Temperature . 24 Thermal Stability . 40 Compressive Properties . 24 Heat Aging . 40 Compressive Strength Testing (ASTM D695) . 24 Test procedures . 40 Stress-strain curves . 25 Results . 40 Compressive Modulus Testing (ASTM D695) . 26 Thermogravimetric Analysis (TGA) . 42. Compressive Strength Testing (ISO 604) . 26 Combustion Properties . 43 Compressive Modulus Testing (ISO 604) . 26 Glow Wire Testing . 43 Conclusions . 26 Flammability per UL 94 . 44 Shear Properties . 27 Horizontal burning test . 44 Test Method . 27 50 W (20 mm) vertical burn test . 44 Results . 27 500 W (125 mm) vertical burning test . 44. Oxygen Index . 45 Impact Properties . 28 Test Method . .45 Notched Izod . 28 Result . 45 Unnotched Izod . 29 Commercial Aircraft Tests . 45 Falling Weight Impact Tests . 29 Vertical burn . .45 Instrumented impact testing . .29 Smoke density . 45 Toxic gas emissions . 46 Heat release rate (Ohio State) (OSU) . 46 KetaSpire® PEEK Design and Processing Guide / 1 Electrical Properties . .47 . Weathering . 61 Test Method . 61 Dielectric Breakdown Voltage Results . 61 and Strength . 47 Appearance and color . 61 Volume Resistivity . 47 Mechanical properties . 61 Conclusions . 62 Surface Resistivity . 48 Water Absorption . 63. Dielectric Constant . 48 Dissipation Factor . 48 Design Principles . 64 UL 746A Short-Term Properties . 48 Mechanical Design . 65 High-Voltage, Low-Current, Dry Arc Using Classical Stress-Strain Equations . 65 Resistance – ASTM D495 . 48 Limitations of Design Calculations . 65 Comparative Tracking Index (CTI) – Deflection Calculations . .65 ASTM D3638 . 49 Stress Calculations . 68 High-Voltage Arc Tracking Rate (HVTR) . 49 Reinforcing Fiber Orientation Considerations . 69. Hot Wire Ignition (HWI) - ASTM D3874 . 49 Designing for Equivalent Part Stiffness . 69 High-Current Arc Ignition (HAI) . 49 Changing section thickness . 69 High-Voltage Arc Resistance to Ignition . 50 Adding Ribs to Maintain Stiffness . 70 Designing for Sustained Load . 70 Considering Stress Concentrations . 71 Environmental and Chemical Resistance . 51 Computer Aided Engineering (CAE) . 71 Chemical Resistance . 51 Injection Molding Simulation . 71 Immersion Testing . 51 Finite Element Analysis (FEA) . 72 Stress Testing . 52 Coupling the Injection Molding and Transportation Fluid Resistance . 52 Mechanical Simulations . 72 Aircraft Fluids . 52 Designing for Assembly . 72 Skydrol® LD-4 hydraulic fluid . 52 Interference or Press Fits . 72 Jet Fuel A/A-1 (ASTM D1655) . 52 Calculating the Allowable Interference . 73 Automotive Fluids . 54 Mechanical Fasteners . 73 Automatic transmission fluid . 54 Self-tapping screws . 74 Automotive brake fluid . 55 Improving torque retention . 74 Motor oil . 55 Tightening torque . 74 Oil and Gas Fluids Resistance . 55 Pull out force calculation . 75 Test Procedure . 56 Threaded inserts . 75 Results . 56 Molded-in threads . 75 Conclusions . 56 Designing with Snap Fits . 75 Straight cantilever beam equation . 76 Sterilization Resistance . 58 Tapered Cantilever Beam Equation . 77 Gamma Radiation . 58 Test procedures . 59 Designing for Injection Molding . 77 Electron Beam . 59 Wall Thickness . 77 Test procedures . 59 Wall Thickness Variation . 77 Ethylene Oxide . 59 Draft Angle . 77 Test procedures . 59 Ribs . 78 Low Temperature Hydrogen Peroxide Coring . 78 Sterilization . 59 Bosses . 79 Test procedures . 60 Steam Autoclaving . 60 Test procedures . 60 2 \ KetaSpire® PEEK Design and Processing Guide Processing . 80 Wire and Cable Extrusion . 98 Equipment . 98 Rheological Properties . 80 Extruder . 98 Injection Molding . 82 Die and crosshead design . 98 Equipment . 82 Downstream equipment . 99 Injection molding machine . .82 Processing . 99 Clamping pressure . 83 Drying . 99 Screw design . 83 Temperature setup . 99 Nozzle . 83 Startup . 99 Tooling . 83 Shut-down . .99 Tool steel . 83 Purging . 99 Tool types . 83 Compression Molding . 101 Cavity Layout . 84 Material Selection . 101 Side action . 84 Equipment . 101 Sprue and runner systems . 85 Vertical press . 101 Hot runner systems . 85 High intensity mixer . 101 Mold Shrinkage . 85 Drying oven . 102 Gating . 85 Tooling . 102 Gate types . 85 Temperature control . 102 Gate location . 86 Compression Molding Process . 103 Gate size . 86 Venting . 86 Draft . 87 Secondary Operations . 104 Ejector systems . 87 Joining . .104 Thermal Management . 87 Welding . 104 Starting Point Molding Conditions . ..