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Plastics 101

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Plastics 101

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    4. Definition of Plastics Plastics are classified into two categories Thermoset – any material that once heated cannot be reheated or reformed Thermoplastic – any material that can be heated and reheated to make a finished part or stock shape Plastics are also broken down into two subcatagories of amorphous or crystalline. This molecular structure is very important to the performance properties of any plastic material

    5. Plastics Definition Thermoset material examples: Phenolic – Micarta C, CE, L, LE, XXX paper Bakelite, Melamine Glass Epoxy systems – G9, G10, G11 Polyester composites – Ultracomp Teflon - PTFE Torlon PAI Vespel/Meldin PI Celazole - PBI

    6. Plastics Definitions Thermoplastic Examples: PVC PEEK Polyethylene IM PAI - Torlon Polypropylene IM PI – Vespel, Aurum, Meldin Nylon PPS -Techtron Acetal – Delrin/Acetron Acrylic Polycarbonate – Lexan PPO - Noryl PEI – Ultem Sulphones PET – Ertalyte PU - Polyurethane PBT – Valox Fluoropolymers – PFA, ETFE, PVDF, FEP, ECTFE, CTFE

    7. Plastic Processing Thermoset materials can only be compression or transfer molded. Process usually requires extremely high pressures and elevated temperatures during compression Thermoset materials usually require some form of reinforcement for stability and strength Additives include paper, cotton fiber, linen fiber, fiberglass, polyester fiber, Kevlar fiber, carbon fiber

    8. Plastic Processing Thermoplastics can be extruded, injection molded, compression molded, blow molded, thermoformed, bonded to substrates, stamped and machined. Additives to thermoplastics enhance many properties: Wear and friction Electrical properties – insulative, conductive, dissipative Fire resistance Increases in compressive, tensile and flexural strength and moduls Improvements in impact strength

    9. Plastic Processing Additives come in many forms: Fibers made from glass, graphite, polyester, Kevlar, carbon – all increase physical strength of the material Minerals such as MOS2, carbon black, graphite powder, calcium carbonate, calcium silicate, boron nitride, coke flour improve physical strength but also improve wear, thermal and electrical properties. Chemical additives such as fire retardants, lubrication media such as PTFE, UV stabilizers all improve the performance properties

    11. Commodity Plastics Classified as materials with operating temperatures below 200°F Generally have low physical properties Good chemical resistance in most cases Used as light duty structural parts, media transfer components such as pump bodies, valve bodies, tubing Generally low cost at the resin level – $0.50 to 2.50 per lb.

    12. Commodity Plastics Materials included in this product category include: LDPE, MDPE, HDPE – all polyethylene except UHMW-PE Polypropylene – at the edge of the performance line as PP is used in many engineering applications in difficult chemical environments – Michelin BCM Trace Material - Isosud PP Polystyrene – drinking cup material but used in some structural components PVC – rigid and flexible versions – Michelin BCM Trace Material - Isosud PVC ABS – another borderline material because ABS is easily alloyed with other engineering grades to produce an excellent structural material. Often alloyed with polycarbonate and is a common material in automotive applications Polyurethane – rigid or flexible versions, ester or ether based compounds Michelin BCM Trace Material - Courbhane 53B, 65B, 85V Acrylic PMMA – Rigid see through material for site glass or shields, available with scratch resistant coatings Michelin BCM Trace Material - Altuglas CN, EX

    14. Engineering Plastics Classified as materials with continuous operating temperatures up to 300°F Generally much stronger and more versatile than commodity plastics. Used in structural and wear applications Available with enhancements to fit broader demands for service Costs run between $1.50 – 25.00 per pound

    15. Engineering Plastics Materials included in this category include: Nylons – Type 6, 6-6, 6-11, 6-12 and 4-6 – available in extruded, compression molded and cast versions. Easy to machine and low cost. Michelin BCM Trace Materials – Ertalon 6SA, 6XAU, Sustamid 6, Ertalon 66SA Acetals – homopolymer (Delrin), copolymer (Acetron) – available in extruded rod, compression molded sheet and extruded film. Comes with glass additives for strength, chemical lubricants, PTFE for wear and friction properties. Michelin BCM Trace Materials – Ertacetal C, Ertacetal H, Sustarin C PPO – Noryl – excellent material for electrical properties and high strength without fillers PC – polycarbonate, high strength “see through” product for site panels, lenses, bullet proof glass, medical/dental devices Michelin BCM Trace Materials – PC1000, Makrolon 099

    16. Engineering Plastics Materials included in this category: PET – polyester base, FDA, NSF, USDA structural material. Also available in bearing grade with food grade lubricant Michelin BCM Trace Material - Ertalyte, Ertalyte TX PBT – polyester base, similar to PET but with improved chemical resistance and impact strength UHMW-PE – borderline temperature but classified as an engineering grade because of it’s unique performance properties. Excellent wear material, zero moisture absorption and very low friction. Michelin BCM Trace Material – Cestidur, Polystone M Epoxy Mat, Phenolic Mat Materials – glass, cotton, linen, paper reinforced resin systems Michelin BCM Trace Materials – Delterm HT, Glastherm HT, Thermalite, Delmat, Permaglas, Pamitherm, Vetrotherm

    18. High Performance Materials Classified as materials that will perform above 300°F Associated with the most extreme operating conditions Temperatures up to 850°F Broad chemical resistance Superior physical strength with some materials better than 7:1 strength to weight ratios Excellent inherent wear properties Thermally stable Costs range from $25-200.00 per pound

    19. High Performance Materials Main advantages of the High Performance Polymers Higher allowable service temperature Better retention of rigidity and creep resistance over a wider temperature range Better dimensional stability Better chemical resistance Better Hydrolysis resistance Better resistance to gamma and x-ray exposure Better flammability ratings

    20. High Performance Materials Materials included in this category: PTFE – all filled versions and chemical deviations Michelin BCM Trace Material – PTFE - 3P PEEK – high strength, low friction, very good thermal properties Michelin BCM Trace Material – Ketron 1000, Sustatec Sulfones – PES, PSU, PS – all amorphous, good structural properties, microwave transparent, excellent in steam and most chemicals, “see through” product PEI – Ultem – another amorphouse product, commonly used in medical and dental devices due to steam autoclave requirements, microwave transparent and good gamma radiation resistance PPS – Ryton, Techtron – excellent strength, chemical resistance, low moisture absorption – bearing grades show very good wear properties Michelin BCM Trace Material – Techtron HPV

    21. High Performance Materials PAI – Torlon – versatile, high end material with excellent strength, continuous 485°F operation – excellent dielectric properties and wear versions are the best in the industry Michelin BCM Trace Material – Torlon 4301, Torlon 4203 PI – Vespel/Meldin/Duratron – Extreme temperature conditions up to 700°F, excellent wear properties, poor service in steam but good in other chemical environments. Low outgassing in vacuum so commonly used in semiconductor production PBI – the gold standard for plastics – service up to 850°F in air, short term to 1100°F, excellent wear properties, thermal expansion same as steel for precision design of bearings

    24. Celazole - PBI The most expensive of all plastic materials and also the highest temperature rating at nearly 800F and short term to 1300F

    42. Fluoropolymers Family of materials based on carbon/fluorine chemistry Best known material in this family is PTFE PTFE is a granular form of fluoropolymer that must be cold compression molded, free sintered and machined. PTFE can not be injection molded. PTFE can also be extruded into rods and tubes. Modifications of carbon/fluorine structure by adding or subtracting fluorine and replacing with ethylene or chlorine produces melt process resins

    43. Fluoropolymers ECTFE ETFE PCTFE (Kel-F)? PFA MFA TFM Teflon AF All of these products can be injection molded or melt processed to produce finished parts or stock shapes as extrusions or sheet.

    44. Fluoropolymers - Properties Very broad temperature range – 450 to +550F Chemically inert Good mechanical strength Very low friction Excellent dielectric properties Excellent thermal insulator

    45. Fluoropolymers - Applications With the addition of various fillers, such as carbon, glass, polymers, graphite, MOS2 and metallic oxides, fluoropolymers can be made stronger with improved thermal properties, bearing load carrying capabilities, better wear properties and variable electrical capabilities. Applications include bearings, seals, vanes, thermal and electrical insulators, gaskets, diaphragms and standoffs.

    46. Rulon™High Performance PTFE Products Rulon is a family of blended PTFE products Rulon is available in over 30 compounds as rod, tube, sheet, tape or machined parts Rulon Characteristics -450 - +550F Chemically inert Excellent wear life Excellent dielectrics Low friction Bearing grades are self lubricating for dry applications

    47. RULON PROPERTIES Outstanding wear properties in dry applications Chemically compatible in full pH spectrum. Exception is molten sodium Very low inherent friction .05-.30 PV ratings – 10,000 with SFPM capacity to 400 Near zero outgassing in vacuum Some food/drug grades available Variety of fillers used to improve wear, friction, compatibility with mating hardware Excellent thermal and electrical insulative properties

    50. So What Material Do I Use???? The process for determining which material is appropriate for an application is a step by step procedure. 1. Is the application for a structural component or wear component? 2. What temperatures will the part see? 3. What are the physical demands on the part? 4. For bearing applications, what are the bearing loads, speeds, PV? 5. What is the environmental condition? 6. What are the cost considerations? 7. What is the service life expectation?

    51. What material…… If the part is structural, what are the key considerations? Is the part in tension, compression or flex? Is the part exposed to water, chemicals, dirt, grit, sunlight, ozone, UV, gamma radiation, microwave, etc. Does the part require close tolerances? Does the quantity justify special processing such as injection molding, direct forming or automolding? Does the final material selected meet the life and cost expectancy for the part?

    52. What material……. If the part is a wear application: 1. Is there a friction issue that needs to be addressed? 2. What is the bearing load? 3. What is the speed? Is it linear, oscillating or rotary? 4. What is the combined load/speed factor? PV 5. What is the environment the bearing will perform in? 6. Is there impact or vibration? 7. What is the life expectancy of the bearing? 8. Is this a zero or close to zero maintenance requirement?

    53. Where do we apply plastics in bearings??

    54. Where do we apply plastics in bearings?

    55. Where do we apply plastics in structural components?

    56. Where do we apply materials in structural components?

    57. Plastic Materials Are Versatile! With the correct material selection, there are few applications where plastics can’t be a cost effective, easy to apply alternative to metals. All structural and bearing applications of plastics are purely a material selection process. Understand the limitations and you will understand the capabilities.

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