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transcript
9/5/14
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CONDUCTIVE • FLAME RETARDANT •FILM/SHEET STRUCTURAL • ELASTOMERS • WEAR • COLOR
Tough or Strong? Short or Long?
Dialing in Mechanical Properties
Brennan Ashton Structural Product Development Engineer
RTP Company
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
What are we solving?
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Strength YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Stiffness
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Impact YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Structural Composites Formula
Resin Change in Properties Additives
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Structural Additives: Foundation YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Agenda
• Modifiers
• Fillers
• Lightweighting
• High Temperature Materials
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
In this Presentation
Modifiers Fillers
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Modifiers
Polymer Blends Impact Modifiers
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Polymer Blends
ABS brings • Improved flow • Chemical resistance • Cost reduction
PP brings • Improved flow • Chemical resistance • Cost reduction
PBT brings • Improved flow • Chemical Resistance
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Polymer Blends
PC brings • Toughness • Strength
Nylon brings • Strength • Stiffness
PC brings • Toughness • Dimensional stability
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Polymer Blends
PC PC/ABS (RTP 2500 A) ABS
Specific Gravity 1.19 1.15 1.05
Tensile Strength (MPa) 59 59 45
Notched Izod Impact (J/m) 850 740 250
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Polymer Blends
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
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Polymer Blends
Applications in Automotive
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Modifiers
Impact Modifiers
Impact properties
Strength Stiffness
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Impact Modifiers
PA 6/6 IM PA 6/6
Specific Gravity 1.14 1.08
Notched Izod Impact (J/m) 55 900
Tensile Strength (MPa) 80 45
Flexural Modulus (MPa) 2.8 1.8
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Impact Modified
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
Automotive Ex.: Airbag Housings
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Impact Modifiers
Limitations
Base resin
Environment
Lose Performance
Temperature
Chemical Resistance
UV Resistance
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
In this Presentation
Modifiers Fillers
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Fillers
Beads (Glass) (photo: Potters, Inc.)
Minerals (Talc)
Fibers (Glass)
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Fillers
Property change determined by:
Aspect Ratio Reinforcing
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Low Aspect Ratio
Beads (Glass) (photo: Potters, Inc.)
Aspect Ratio = 1
PC PC + 10% Glass Beads
PC + 30% Glass Beads
Specific Gravity 1.19 1.27 1.42
Tensile Strength (MPa) 59 55 48
Notched Izod Impact (J/m) 850 100 80
Flexural Modulus (MPa) 2.4 2.6 3.4
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Low Aspect Ratio
Minerals (Talc)
Aspect Ratio = 2-50
PP PP + 20% Talc
PP + 40% Talc
Specific Gravity 0.91 1.05 1.25
Tensile Strength (MPa) 32 32 30
Notched Izod Impact (J/m) 47 45 34
Flexural Modulus (MPa) 1.5 2.5 3.8
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Shrink Rate x = Shrink Rate y Flat Part
Warp Control YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Low Aspect Ratio
Application: Key Fob Problem: Dimensional stability Solution: PA66 + Glass Beads Benefit: Uniform shrinkage
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
High Aspect Ratio
Fibers (Glass)
Aspect Ratio = 50-250
PC PC + 30% Glass Beads
PC + 30% Glass Fiber
Specific Gravity 1.19 1.42 1.42
Tensile Strength (MPa) 59 48 124
Notched Izod Impact (J/m) 850 80 160
Flexural Modulus (MPa) 2.4 3.4 7.6
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
High Aspect Ratio
Fibers (Glass)
Aspect Ratio = 50-250
PP PP + 40% Talc
PP + 40% Fiber
Specific Gravity 0.91 1.25 1.22
Tensile Strength (MPa) 32 30 84
Notched Izod Impact (J/m) 47 34 108
Flexural Modulus (MPa) 1.5 3.8 7.5
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Non-Uniform Shrink = Warp
Shrinkage X1 & X2 ≠ X3 Warp
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Strength & Warp Control
Shrinkage X1 = X2 = X3 Flat Part
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
High Aspect Ratio
Application: Air Registers Problem: Stiffness and
dimensional stability Solution: Glass Fiber/Mineral
Filled PP Benefit: High strength, Great
Surface Finish
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Improvements in SGF PP
84
114 124
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
Tens
ile S
tren
gth
(MPa
)
40% SGF PP RTP High Perf. PP 40% VLF PP
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Improvements in SGF PP
7500
8200
8400
7000
7200
7400
7600
7800
8000
8200
8400
8600
Flex
ural
Mod
ulus
(MPa
)
40% SGF PP
RTP High Perf. PP
40% VLF PP
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Improvements in SGF PP
12.1
15.8
22.6
0.0000
5.0000
10.0000
15.0000
20.0000
25.0000
Impa
ct S
tren
gth
(kJ/
m2 )
RTP 0107 CC
RTP High Perf. PP
70836 A
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Extreme Aspect Ratio
Long Glass Fiber
Aspect RaRo = 300+
PP + 40% Short Glass
PP + 40% Long Glass
Specific Gravity 1.22 1.22
Tensile Strength (MPa) 84 124
Notched Izod Impact (J/m) 108 228
Flexural Modulus (MPa) 7.5 8.4
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Pellet Comparison
3 mm
11 m
m
Fiber Length ~ 1-2 mm
11 mm
Short Fiber VLF
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Secret to Success: The Skeleton
PA 66 + 60% VLF Seat Belt Tensioner Housing
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Polyamide 6/6 – 40% Glass Fiber
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
VLF Applications in Automotive YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Hollow Glass Microspheres
• Lightweighting where properties are less demanding
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Hollow Glass Spheres
1.14
0.89 0.85
1.50 1.36
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
1.60
Unfilled PA 6/6 PA 6/6 w/ Glass Bubbles
High Impact PA 6/6 w/ Glass Bubbles
PA 6/6 w/ 40% mineral
PA 6/6 w/ 30% glass fiber
Specific Gravity
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Hollow Glass Spheres
90
48
34
69
190
1.14 0.89 0.85 1.5 1.36 0
20
40
60
80
100
120
140
160
180
200
Unfilled PA 6/6 PA 6/6 w/ Glass Bubbles
High Impact PA 6/6 w/ Glass Bubbles
PA 6/6 w/ 40% mineral
PA 6/6 w/ 30% glass fiber
Tensile Stren
gth (M
Pa)
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Hollow Glass Spheres
43
20 25
43
80
1.14 0.89 0.85 1.5 1.36 0
10
20
30
40
50
60
70
80
90
Unfilled PA 6/6 PA 6/6 w/ Glass Bubbles
High Impact PA 6/6 w/ Glass Bubbles
PA 6/6 w/ 40% mineral
PA 6/6 w/ 30% glass fiber
Notched
Izod
(J/m
)
CONDUCTIVE • FLAME RETARDANT •FILM/SHEET STRUCTURAL • ELASTOMERS • WEAR • COLOR
Carbon Fiber
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Carbon Fiber
Fiber E-‐Glass Fiber Std. Modulus Carbon Fiber
Typical Diameter (μm) 10-‐17 5-‐10
Density (g/cm3) 2.55 1.81
Est. Tensile Strength (MPa) 3400 4100
Est. Flexural Modulus (MPa) 73 240
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Carbon Fiber - Polypropylene
PP 40% GF PP 40% VLF PP 30% CF
Tensile Strength (MPa) 85 120 105
Flexural Modulus (MPa) 6900 8250 11800
Notched Izod Impact (kJ/m2) 12.1 22.8 10.2
Specific Gravity 1.21 1.21 1.06
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Fiber Comparison – PA 6/6
PA 6/6 60% VLF (Long Fiber)
PA 6/6 35% Carbon Fiber
Flexural Modulus (MPa) 19.3 19.0
Tensile Strength (MPa) 275 244
Tensile ElongaRon (%) 2.0 2.0
Specific Gravity 1.71 1.29
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Fiber Comparison – PPS
PPS 40% Glass PPS 20% Carbon
Flexural Modulus (MPa) 15.1 15.8
Tensile Strength (MPa) 169 172
Tensile ElongaRon (%) 1.5 1.0
Specific Gravity 1.68 1.40
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
High Temperature Polymers
Amorphous Polyetherimide (PEI)
Polyethersulfone (PES)
Polysulfone (PSU)
Polycarbonate (PC)
Acrylonitrile Butadiene Styrene (ABS)
Styrene Acrylonitrile (SAN)
Polystyrene (PS)
High Impact Polystyrene (HIPS)
Acrylic (PMMA)
Semi-Crystalline Polyetheretherketone (PEEK)
Polyphenylene Sulfide (PPS)
Polyphthalamide (PPA)
Polyethylene Terephthalate (PET)
Polybutylene Terephthalate (PBT)
Polyamide (PA/Nylons)
Acetal (POM)
Polypropylene (PP)
Polyethylene (HDPE, LDPE, LLDPE)
Thermal &
Cost Increases
High Performance Engineering Commodity
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Chemical Structure
Polyethylene Tg -5 °F
Polyimide Tg 482 °F
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Tg
Amorphous
Semicrystalline
• Tg = the softening point. – There is a drop in strength and modulus above the Tg – Crystalline materials will tend to creep above the Tg – Amorphous materials will start to flow above the Tg
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Amorphous Materials
0
2000
4000
6000
8000
10000
12000
14000
0 50 100 150 200 250 300 350 400 450 500
Flexural M
odulus, M
Pa
Temperature, °F
Flexural Modulus Vs. Temperature
40% GF PSU 40% GF PES 40% GF PEI
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Semi-Crystalline Materials
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
0 50 100 150 200 250 300 350 400 450 500
Flexural M
odulus, M
Pa
Temperature, °F
Flexural Modulus Vs. Temperature
40% GF PPA 40% GF HTN 40% GF PEEK 40% GF PPS 40% GF TPI
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Elevated Temp Properties
0
20
40
60
80
100
120
140
160
180
0 0.02 0.04 0.06 0.08
40% Glass fiber filled Polypropylene
Typical DAM @ -40 C
Typical DAM @ 23 C
Typical DAM @ 65 C
Typical DAM @ 107 C
0
50
100
150
200
250
0 0.02 0.04 0.06 0.08
40% Glass fiber filled Nylon 6/6
Typical DAM, -40 C
Tyical DAM, 23 C
Typical DAM, 65 C
Typical DAM, 121 C
0
50
100
150
200
250
300
0 0.02 0.04 0.06 0.08
40% Glass fiber filled PPA
Typical DAM, -40 C
Typical DAM, 23 C
Typical DAM, 65 C
Typical DAM, 176 C
Strain – mm/mm
Stre
ss -
MPa
Multiple Temperature Tensile Stress/Strain
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Flexural Modulus
0
5000
10000
15000
20000
25000
30000
35000
PEI PPS PPA PEEK
Flexural M
odulus (M
Pa)
High Temp Resin
50% GF
50% VLF
40% CF
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Impact – Izod Notched
0
50
100
150
200
250
300
350
400
PEI PPS PPA PEEK
Impa
ct -‐ Notched
Izod
(J/m
)
High Temp Resin
50% GF
50% VLF
40% CF
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
High Temperature Applications
Application: Multiple Components on V-22 Osprey Problem: Environment Solution: Carbon fiber reinforced TPI and PEEK Benefit: Flame retardant, temperature resistance, strength/stiffness
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Tensile Strength
0
50
100
150
200
250
300
350
400
PEI PPS PPA PEEK
Tensile Stren
gth (M
Pa)
High Temp Resin
50% GF
50% VLF
40% CF
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Tensile Strength
0
50
100
150
200
250
300
350
400
PEI PPS PPA PEEK
Tensile Stren
gth (M
Pa)
High Temp Resins
50% GF
50% VLF
40% CF
40% UP CF
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
High Performance Application
Application: Brake Rotor Measuring Probe
Problem: Casting replacement Solution: Carbon fiber reinforced
PPA Benefit: High strength and
stiffness
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Summary
• Modifiers – Polymer Blends – Impact Modifiers
• Fillers – Performance driven by aspect ratio
• High Temperature – Wide range of polymers with varying performance – Understanding environment and stress levels is key to
success
CONDUCTIVE • FLAME RETARDANT •FILM/SHEET STRUCTURAL • ELASTOMERS • WEAR • COLOR
Questions?
Brennan Ashton bashton@rtpcompany.com