tough or strong? short or long? dialing in mechanical ... · avity your global compounder of custom...

9/5/14

1

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?


Strength YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS

Stiffness

9/5/14

2


Impact YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS

Structural Composites Formula

Resin Change in Properties Additives


Structural Additives: Foundation YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS

Agenda

•  Modifiers

•  Fillers

•  Lightweighting

•  High Temperature Materials

9/5/14

3


In this Presentation

Modifiers Fillers


Modifiers

Polymer Blends Impact Modifiers


Polymer Blends

ABS brings •  Improved flow •  Chemical resistance •  Cost reduction

PP brings •  Improved flow •  Chemical resistance •  Cost reduction

PBT brings •  Improved flow •  Chemical Resistance


Polymer Blends

PC brings •  Toughness •  Strength

Nylon brings •  Strength •  Stiffness

PC brings •  Toughness •  Dimensional stability

9/5/14

4


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


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


Polymer Blends

Applications in Automotive


Modifiers

Impact Modifiers

Impact properties

Strength Stiffness

9/5/14

5


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


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


Impact Modifiers

Limitations

Base resin

Environment

Lose Performance

Temperature

Chemical Resistance

UV Resistance


In this Presentation

Modifiers Fillers

9/5/14

6


Fillers

Beads (Glass) (photo: Potters, Inc.)

Minerals (Talc)

Fibers (Glass)


Fillers

Property change determined by:

Aspect Ratio Reinforcing


Low Aspect Ratio

Beads (Glass) (photo: Potters, Inc.)

Aspect Ratio = 1

PC PC + 10% Glass Beads

PC + 30% Glass Beads




Flexural Modulus (MPa) 2.4 2.6 3.4


Low Aspect Ratio

Minerals (Talc)

Aspect Ratio = 2-50

PP PP + 20% Talc

PP + 40% Talc





9/5/14

7


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


High Aspect Ratio

Fibers (Glass)

Aspect Ratio = 50-250

PC PC + 30% Glass Beads

PC + 30% Glass Fiber






High Aspect Ratio

Fibers (Glass)

Aspect Ratio = 50-250

PP PP + 40% Talc

PP + 40% Fiber





9/5/14

8


Non-Uniform Shrink = Warp

Shrinkage X1 & X2 ≠ X3 Warp


Strength & Warp Control

Shrinkage X1 = X2 = X3 Flat Part


High Aspect Ratio

Application: Air Registers Problem: Stiffness and

dimensional stability Solution: Glass Fiber/Mineral

Filled PP Benefit: High strength, Great

Surface Finish


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

9/5/14

9



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



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


Extreme Aspect Ratio

Long Glass Fiber

Aspect RaRo = 300+

PP + 40% Short Glass

PP + 40% Long Glass



Notched Izod Impact (J/m) 108 228



Pellet Comparison

3 mm

11 m

m

Fiber Length ~ 1-2 mm

11 mm

Short Fiber VLF

9/5/14

10


Secret to Success: The Skeleton

PA 66 + 60% VLF Seat Belt Tensioner Housing


Polyamide 6/6 – 40% Glass Fiber


VLF Applications in Automotive YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS

Hollow Glass Microspheres

•  Lightweighting where properties are less demanding

9/5/14

11


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



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





Tensile Stren

gth (M

Pa)



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





Notched

Izod

(J/m

)


Carbon Fiber

9/5/14

12


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


Carbon Fiber - Polypropylene

PP 40% GF PP 40% VLF PP 30% CF


Flexural Modulus (MPa) 6900 8250 11800

Notched Izod Impact (kJ/m2) 12.1 22.8 10.2



Fiber Comparison – PA 6/6

PA 6/6 60% VLF (Long Fiber)

PA 6/6 35% Carbon Fiber



Tensile ElongaRon (%) 2.0 2.0



Fiber Comparison – PPS

PPS 40% Glass PPS 20% Carbon



Tensile ElongaRon (%) 1.5 1.0


9/5/14

13


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


Chemical Structure

Polyethylene Tg -5 °F

Polyimide Tg 482 °F


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


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

9/5/14

14


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


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


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


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

9/5/14

15


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


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


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


High Performance Application

Application: Brake Rotor Measuring Probe

Problem: Casting replacement Solution: Carbon fiber reinforced

PPA Benefit: High strength and

stiffness

9/5/14

16


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


Questions?

Brennan Ashton [email protected]

tough or strong? short or long? dialing in mechanical ... · avity your global compounder of custom...

Documents