Wear Resistant Thermoplastic Compounds - SINTEF · 2014. 11. 17. · Wear of POM, PA 6/6 and PC....
Transcript of Wear Resistant Thermoplastic Compounds - SINTEF · 2014. 11. 17. · Wear of POM, PA 6/6 and PC....
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CONDUCTIVE • FLAME RETARDANT •FILM/SHEET STRUCTURAL • ELASTOMERS • WEAR • COLOR
Wear Resistant Thermoplastic Compounds
Dr. Joel BellProduct Development Engineer
RTP Company
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICSYOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Agenda
• RTP Company Introduction• Definitions & Test Methods• Morphology • Additive Technologies• Application examples
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Asia United States France
• Scalability: Develop your solution on a small scale and produce your solution at larger quantities
• Plant-to-plant consistency
• Identical machinery, processing, QA testing
• ISO 9001:2008 Registered Facilities
• Worldwide technical support
• Local customer service: real people, real time
GLOBALIZATION STRATEGY
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICSYOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
STRUCTURAL WEAR RESISTANT CONDUCTIVE ELASTOMERS
FILM/SHEETCOLORFLAME RETARDANT
PRODUCT FAMILIES
Compounds formulated to meet your needs
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CONDUCTIVE • FLAME RETARDANT •FILM/SHEET STRUCTURAL • ELASTOMERS • WEAR • COLOR
Definitions
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICSYOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Tribology Definition
The Science of the mechanisms of friction, lubrication, and wear of interacting surfaces that are in relative motion.
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Mechanisms of Wear
Adhesive WearThe primary mechanism for thermoplastic wear.Characterized by transfer of material from one part to the other caused by frictional heat.
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Mechanisms of Wear
Abrasive wearCaused by a hard material scraping or abrading away at a softer material.Characterized by grooves cut or gouged into the surface. Three Body
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Coefficient of Friction (µ)
Friction is the natural resistance to the sliding motion of one surface over another
Static Coefficient of Friction (µs) = Fx/FyFx = Force to initiate motionFy = Normal force holding surfaces together
Dynamic Coefficient of Friction (µk) = Fx/FyFx = Force to sustain motionFy = Normal force holding surfaces together
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Slip/Stick
Thermoplastics Are Unique Static friction is typically less than dynamic friction
• Can Lead To Slip/Stick
Too large of difference leads to squeaking
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ASTM D1894 Friction Test
• Sled Test– Coefficient of Friction Testing– Does not determine wear resistance
• Can Show Slip/Stick
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ASTM D3702 Wear Test
Standard conditions• Steel Thrust Washer• 40 psi: 50 ft/min (2000 PV)• Ambient Temp• 100 hour test
Counter-surface (thrust washer) material, pressure, velocity and temperature are all adjustable
The best use of this test is to perform comparative screening of multiple candidate materials
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ASTM D3702 Wear Tester
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Calculating Wear Factor (K)
Wear Factor (K)
K = W/(F x V x T)
K = Wear Factor: (in3-min/ft-lb-hr)∙10E-10 or (mm3/N-m)∙10E-8F = Force: lb or NV = velocity: ft/min or m/secT = Elapsed Time: hr or secW = volume wear: in3 or mm3
Wear factor per unit pressure can be calculated by multiplying the standard wear factor value by 0.35in2. KP = Wear Factor: (in5·min/ft-lb-hr)∙10E-10(Some companies report wear factors this way)
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CONDUCTIVE • FLAME RETARDANT •FILM/SHEET STRUCTURAL • ELASTOMERS • WEAR • COLOR
Additive Technologies
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICSYOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Amorphous Semi-CrystallineLow Shrinkage XLow Warpage XTight Tolerances XTransparency XMold Flow Ease XChemical Resistance XResponse to Reinforcement XWear Resistance X
Morphology Characteristics
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Traditional Technologies
• Workhorse additive – solid white powder
• Homogeneously distributed throughout the polymer matrix
• Forms a lubricious layer at polymer surface – Requires a “Break-in” period
• Compatible with nearly all thermoplastic resins
1. PTFE – Polytetrafluoroethylene (10-20%)
Drawbacks• Fluorine content
• Die plate-out
• Relatively high loadings
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PTFE Mechanism
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICSYOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Application
Automotive Seat Adjustment Lever Needs good strength, stiffness
and wear resistance. (Structural, wear, precolor)
Glass fiber reinforced PTFE lubricated and precolored PPA.
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Traditional Technologies
• Boundary lubricant which migrates to the surface over time
• Migration rate is viscosity dependent
• Excellent friction reducer• Best in high speed/low load
applications• Used with PTFE to eliminate
“Break-in” period
2. Silicone – Polydimethylsiloxane (1-3%)
Drawbacks• Limited use in decorated parts
• Poor adhesion of paint or print inks
• Bad for electrical applications• Can foul contacts
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PTFE Break-In Period with Silicone
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Industrial Application
Food Handling conveyor rollers Antimicrobial, low friction.
(Antimicrobial, Wear) PTFE and silicone lubricated POM
with antimicrobial additive
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Wear of POM, PA 6/6 and PC
7500
1500 175675 200 102
150 60 400
10002000300040005000600070008000
K
Neat Resin 2% SI 20% PTFE
POMPA 6/6
PC
Additive(s)
Wear Factor (K)POMPA 6/6PC
Values per ASTM D3702 test method vs C1018 Steel
• Wear Factor Units: (in3min/ft/lb/hr)E-10
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Traditional Technologies
• Aqueous environments• Excellent temperature resistance• Black (Charcoal Gray) color
3. Graphite Powder (5-15%)
4. Molybdenum Disulfide – MoS2 (1-5%)• Nucleating agent in nylons:
creates harder surface• High affinity to metal:
smoother mating metal surface = lower wear
Drawbacks• Limited use• Dark color limits colorability• Sloughing type additives
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Application
Water Meter Valve Dimensional stability, potable water
contact - NSF listed. (Structural, Wear)
Graphite lubricated SAN & PS
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• Improved bearing capabilities and wear resistance
• Low cost
Drawbacks• Extremely abrasive to mating
surface
1. Glass Fiber (5-50%)
Fiber Reinforcements
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Fiber Reinforcements
• Greatly improved bearing capabilities• Electrically and thermally conductive• Less abrasive than glass
Drawbacks• High cost• Black color
2. Carbon Fiber (5-50%)
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Technology Combinations
• Typical additive package for high load bearing applications.
• Prevalent in hi temp resin systems
• PPS, PEEK and PPA versions available from RTP
• Available from some resin producers
1. 10/10/10 – Carbon fiber/Graphite Powder/PTFE
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Application
AC Compressor Scroll Seal High temperature, chemical and
wear resistance Carbon fiber reinforced and
PTFE/Graphite lubricated PEEK
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Fiber Reinforcements
• Very gentle to mating material• Improves wear and friction
Drawbacks• Difficult to process• Minimal physical property
enhancement• High cost
3. Aramid Fiber (5-20%)
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Fibers vs. Metal
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APWA
APWA – All Polymeric Wear Additive (5-15%)• Alloys with host polymer• Excellent Plastic vs. Plastic performance (Great for business
machines)• Completely halogen free• Physical properties maintained• No die plate-out• Specific gravity benefits (more parts per lb or kg)
Drawbacks• Limited thermal resistance• Higher cost• Not FDA
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APWA Plastic vs. Plastic wear
145
121
98
31
90
2447 29
020406080
100120140160
K
10% PTFE APWA POMPBT
PA6/6
PC
Additive(s)
Wear Factor (K): APWA vs. PTFE POMPBTPA 6/6PC
Values per ASTM D3702 test method.
• PV = 1000 ft·lb/in2min
• Wear Factor Units: (in3min/ft/lb/hr)E-10
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Business Machine Apps
Thermal Printer Frame High Impact, ESD, wear resistance.
(Conductive, Structural, Wear) Impact modified, conductive PC with
APWA for improved wear resistance
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PFPE
PFPE – Perfluoropolyether Oil (< 1%)• Thermally Stable up to PEEK processing temps• Differentiates RTP Company from others• Physical properties maintained• Minimized die plate-out (improved production efficiencies)• Synergy with PTFE• Specific gravity benefits• Improved fatigue resistance
Drawbacks• Limited effectiveness in amorphous resins• Needs PTFE “kick” to deliver optimum friction reduction
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Wear with Various Modifiers
Wear Factor (K) against Steel
495
190 100222
44 100
10 14 190
50100150200250300350400450500
K
PTFE/SI PTFE/PFPE(<10%)
APWA
POMPA 6/6
PC
Additive(s)
Wear Factor (K)
POMPA 6/6PC
Values per ASTM D3702 test method vs. C1018 Steel•PV = 2000 ft·lb/in2min•Wear Factor Units: (in3min/ft/lb/hr)E-10
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Industrial Application
Agricultural Pump Chemical and Wear Resistance
(Structural, Wear) PFPE lubricated PP
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICSYOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Questions
• Thank you for your attention.• Any questions?
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICSYOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Friction of POM, PA 6/6 and PC
0.65
0.550.45
0.60 0.50
0.350.500.45
0.25
0.000.10
0.200.300.40
0.500.60
0.70
µk
Neat Resin 2% SI 20% PTFE
POMPA 6/6
PC
Additive(s)
Dyanamic Coefficient of Friction POMPA 6/6PC
Values per ASTM D3702 test method vs C1018 Steel
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICSYOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
APWA Plastic vs. Steel wear
326
100
341
100114
4147 19
0
50
100
150
200
250
300
350
K
10% PTFE APWA POMPBT
PA6/6
PC
Additive(s)
Wear Factor (K): APWA vs. PTFE POMPBTPA 6/6PC
Values per ASTM D3702 test method vs. C1018 Steel.
• PV = 2000 ft·lb/in2min
• Wear Factor Units: (in3min/ft/lb/hr)E-10
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICSYOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Industrial Application
Fluid Handling Pump Chemical resistance, high
strength & stiffness. (Structural, Wear)
Glass fiber reinforced, PTFE lubricated PP
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICSYOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Business Machine Application
Digital Printer Cartridge Holder ESD, high strength/stiffness, low
friction/wear. (Conductive, Structural, Wear)
Carbon fiber reinforced, PTFE lubricated PEI
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICSYOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Business Machine Application
Copier Bushings Extremely high temperature
resistance (~260°C), wear resistance. (High Temperature, Wear)
Aramid fiber reinforced, PTFE lubricated TPI
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICSYOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Physical Property Comparison
POM PA 6/6 PCUnfilled PTFE
(20%)Silicone
(2%)Unfilled PTFE
(20%)Silicone
(2%)Unfilled PTFE
(20%)Silicone
(2%)
Specific Gravity 1.41 1.52 1.40 1.14 1.26 1.13 1.19 1.31 1.19
Tensile Strength (psi) 8700 6500 7800 12,000 9500 11,000 8500 7000 8500
Flexural Modulus (psi) 350,000 300,000 350,000 400,000 400,000 400,000 340,000 320,000 350,000
Notched Impact (ft-lb/in) 1.5 1.0 1.5 1.0 1.0 1.0 7.5 3.5 10.5
Testing per ASTM test methods.
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YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICSYOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Physical Property Comparison
POM PA 6/6 PCPTFE/SI PTFE
/PFPE
APWA PTFE/SI PTFE/
PFPE
APWA PTFE/SI PTFE/
PFPE
APWA
Specific Gravity 1.44 1.41 1.39 1.19 1.17 1.12 1.24 1.25 1.16
Tensile Strength (psi) 6500 8000 8000 10500 10500 10000 7500 8000 8000
Flexural Modulus (psi) 300,000 340,000 300,000 400,000 400,000 400,000 300,000 330,000 350,000
Notched Impact (ft-lb/in) 1.2 1.5 1.2 1.2 1.2 1.1 7.5 3.5 10.5
Testing per ASTM test methods.