ENGINEERING PLASTICS&
APPLICATIONS
ALOK KUMAR
CENTRAL INSTITUTE OF PLASTICS ENGINEERING CENTRAL INSTITUTE OF PLASTICS ENGINEERING & TECHNOLOGY,& TECHNOLOGY,
Dismantling of >40 modern European cars reveled that in130 Kg plastics per car– 43% PP, 14% PU, 8%Nylons, 8%PE
USAGE OF PLASTICS IN MODERN CARS
PE
36%
PP
21%
PVC
17%
PET
7%
PS/SAN/ABS
15%
PC
2%Nylon 6 & 66
1%
0.44%
0.43%
0.26%
Acrylics
1%
PE Acetal PP PBT
PET PVC EPS PS/SAN/ABS
Nylon 6 & 66 PC Acrylics
s
79 % Plastics consumed – PE+PP+PVC+Styrene's
GLOBAL PLASTICS USAGE
PP24%
LL/LLDPE17%
GP-HIPS8%
PET4%
EPS3%
PC2%
Other ETPs2%
PVC20%
ABS/SAN6%
HDPE14%
PP PVC LL/LLDPE HDPE GP-HIPS
ABS/SAN PET EPS PC Other ETPs
THERMOPLASTICS IN SE ASIA
PLASTICS END USE PATTERN
Plasticulture
22%
Telecom/elec.16%
Infrastructure
24%
Defence & other
2%
Packageing23%
Health2%
Transport6%
Consumer5%
Area % Consumption
Defense & others 2.0
Consumer Durables
5.0
Transport 6.0
Packaging 23.0
Plasticulture 22.0
Infrastructure 24.0
Telecom/ Electronics
16.0
Health & Medicare
2.0
PLASTICS-THE MATERIAL OF CHOICE
• User Friendly• Versatility• Light-weight• Energy Efficient• Non-corrosive• Aesthetic• Abundant• Recyclable
PLASTICS – Emerging Material to meet
Engineering Application Demands• Density
• MFI (Melt flow Index)
• Mechanical Properties
• Impact Strength
• Stiffness
• Toughness
• Creep Resistance
• Abrasion Resistance
• Tear Resistance
Optical Properties
Gloss Clarity & Opacity
PLASTICS – Emerging Material to meet
Engineering Application Demands
Environmental Stress Cracking Resistance
• Chemical Resistance
Acid Resistance
Alkali Resistance
Hazardous Chem. Resistance
( Pesticide / Insecticide)
Barrier Properties
Water Vapour Transmission Rate
Oxygen Transmission Rate
Aroma Transmission Rate
PLASTICS – Emerging Material to meet
Engineering Application Demands
• Easy Processibility
Printability
Sealing Property
Seal Strength
Cost Effectiveness
Product Design Flexibility
CALASSIFICATION OF PLASTICS
PLASTICS
THERMO-PLASTICS THERMO-SETTING
COMMODITY ENGINEERING
SPECIALITY
DEFINATION
COMMODITY THERMOPLASTICS
Very High Volume, Low cost,Low strength, Low Heat Distortion Temp.
ENGINEERING PLASTICS
High strength, High HDT, Low Volume, High Cost
SPECIALITY THERMOPLASTICS
Very Low Volume, Very High Cost, Excels in Specific Performance Requirements.
MAJOR COMMODITY PLASTICS
1. LOW DENSITY POLYETHYLENE (LDPE)
2. LINEAR LOW DENSITY POLYETHYLENE (LLDPE)
3. HIGH DENSITY POLYETHYLENE (HDPE)
4. POLY PROPYLENE (PP)
5. POLY VINYL CHOLORIDE (PVC)
6. POLY STYRENE (PS)
MAJOR ENGINEERING THERMOPLASTICS
1. ACRYLO NITRILE BUTADIENE STYRENE (ABS)
2. STYRENE ACRYLONITRILE (SAN)
3. POLYMETHYL METHACRYLATE (PMMA)
4. POLYAMIDE - (PA)
5. POLYETHYLENE TEREPHTHALATE- (PET)
6. POLYBUTYLENE TEREPHTHALATE- (PBT)
7. POLYOXYMETHYLENE - (POM)
8. POLY CARBONATE - (PC)
9. HIGH IMPACT POLYSTYRENE (HIPS)
MAJOR SPECIALITY PLASTICS
1. POLYTETRA FLUOROETHYLENE (PTFE)2. THEROPLASTIC POLYURETHANE (TPU)3. POLY SULPHONE (PSO)4. POLY ETHER SULPHONE (PES)5. POLYPHENYLENE SULPHIDE (PPS)6. POLYPHENYLENE ETHER (PPE)7. POLY ETHER ETHER KETONE (PEEK)8. POLY ACRYLATE9. POLY AMIDE – IMIDE (PAI)10. POLY ETHER – IMIDE (PEI)11. LIQUID CRYSTAL POLYMERS (LCP)
MAJOR THERMOSET PLASTICS
1. PHENOL FORMALDEHYDE (PF)
2. UREA & MELAMINE FORAMLDEHYDE
3. EPOXY RESINS
4. UNSATURATED POLYESTER RESIN
5. POLYURETHANES
6. SILICONES
0
50
100
150
200
250
300
PC POM PSU PET PEI PES PPS PEEK
Heat Deflection Temperature (°C)
Continuous Use Temperature (°C)
Thermal Properties of ThermoplasticsThermal Properties of Thermoplastics
ABSSAN PS HDPE PP
PC PA 11 PA 6/12 POM PA 6 PA 6/10 PA 6/6 PA 12
TPU PA 6/6 HI PBT TPE PPOPCA – PC/ABS
Commodity
Engineering
High Performance
PEIPSUPESPEEKPPS
LCP
Tem
pera
ture
Mechanical Property retention
CRITERIA FOR PERFORMANCE
TOP SEVEN ENGINEERING PLASTICS
TYPICAL
PROPERTIESPA 6 PC PPO POM PBT PPCP ABS
IZOD Notched
(Kg. cm/cm)
16 85 23 10 6 15 20
HDT (ºc) 104 132 120 110 55 60 82
Water Absorption (%)
1.5 0.15 0.07 0.3 0.08 Neg. 0.4
Flammability
UL94 (1.47mm)
HB V2 HB HB HB HB HB
Sp. Gravity 1.14 1.20 1.06 1.42 1.31 0.9 1.05
Tensile Strength
(Kg/Sq .Cm)
340 600 500 650 500 300 400
Flex. Mod.
(Kg/Sq. Cm)
9500 24000 25000 26000 23000 13000 23000
MAJOR ENGINEERING PLASTICSSTRENGTHS
AMORPHOUS (PC, PPO, ABS)• Constant mechanical properties versus
temperature• Dimensional stability• Creep Resistance• Low Shrinkage• Transparency possible
CRYSTALLINE (PP, POM, PBT/PET)• Resistance to hydrocarbons• Good flow behaviour• Wear and Fatigue resistance
POLYAMIDES
• Several types are available based on raw material used
• Most widely used polyamides are Nylon 6 & 66• Condensation reaction of dicarboxylic acids and
diamins (Commercially through the route of intermediate salts) ---- Nylon 6,& 66
• Ring opening reaction of lactam – Nylon 6, Nylon 12 etc.
• Condensation reaction of amino acids – Nylon 7, Nylon 11 etc.
POLYAMIDES
Characteristics of Polyamides• Semi-crystalline material• Polar in nature• Resistant to hydrocarbon solvents, grease, lubricants• Hygroscopic• High to medium rigidity – improved by glass fibre filling• Good electrical insulation – adversely affected by moisture
absorption.• Good abrasion resistance and low coefficient of friction• Flame retardant versions are difficult process.• Dimensions affected by humidity. • Not good temp. resistance under load – improved by glass
fibre filling.
POLYAMIDES
APPLICATIONS OF POLYAMIDE
• Gear, Cams, bushes, Bearings• Valve Seats• Terminal Blocks• Connectors• Automotive Exterior• Under bonnet Automotive Parts• Motor Housing• Optical fibre Sheathing (Nylon 12)• Insulating liners (Railways• Hair combs
PA In AIR CRAFT
Application: Aircraft Engine ComponentsMaterial: - PA46-GF30
• Highly complex shape minimize the noise level • Design freedom at low costs• High impact properties in a wide temperature range• wall sections as thin as possible- thus reducing valuable weight.
•Airbus
•Injection moulding
PA in Agricultural film Application: Agricultural Barrier FilmMaterial: PA6-unfilled
Barrier Film for agricultural use with environmental benefits.
• When used to cover the soil together with the injection of fumigation chemicals, lower levels of the fumigant can be used. As the film keeps the active agent in the soil for longer.
Extrusion Processing Technology
PA in Automotive, Air/fuel management Application: Air ductMaterial:- PA6-GF20
Blow Molding Processing Technology
Air-duct design offers the best combination of the demanding requirements for: high temperature air ducts.
· higher cold impact than other similar materials· higher stiffness at high temperatures (150°C) allowing thinner walls to be designed.· high melt strength and a low melt viscosity for optimum Production
PA in AUTOMOTIVE, AIR/FUEL MANAGEMENT
Application: Air inlet manifoldMaterial: PA6-GF30
Injection Molding
Ford UK
PA6: The material of choice for air inlet manifolds
• ‘Fuel economy’ & ‘weight reduction’• Single molding and replacing aluminium and steel
by plastics • Provides the chemical, temperature and vibration
resistance required to survive the expected life of vehicles.
• lower system costs compared to metals through part and function integration,
• Easier assembly and longer tool life. • Temperature resistance and a higher burst pressure
resistance after welding.• Providing safer solutions or more design freedom,
as well as lower system costs as a result of an easier• Processibility and better surface appearance.
POLY CARBONATE
POLYCARBONATE
• Poly carbonate was first developed in the laboratory of GE in 1953.
• It was first commercialised in 1958 by GE under the Trade name of LEXAN
• Polycarbonate Lexan is an ester of carbonic acid.• LEXAN is commercially produced by
polycondesation of Bisphenol A and Phosgene
POLY CARBONATE
CHARACTERISTICS :• Highest impact strength• High rigidity• High dimensional stability• High heat distortion temp• Usability in the temperature range of -50 deg. To 135 deg.• Flame retardancy and low combustibility• High optical clarity• Good electrical insulation properties• Good strain resistance• Low water absorption• Food grades available. • Good low temp. impact strength
POLY CARBONATE
APPLICATIONS:• AUTOMOTIVE HEADLAMPS, REFLECTORS AND LENSES• INDICATORS AND BLINKERS• DASH BOARD COMPONENTS• CRASH HELMETS• TELECOM CONNECTORS• DOMESTIC ELECTRICAL SWITCHES• TRAFFIC SIGNAL LENSES• SIGNAL HOUSINGS• TELEGRAPHIC POLE INSULATOR• TERMINAL BLOCKS• LIGHT DIFFUSER• STREET LAMP CANOPIES• BUSINESS MACHINE COMPONENTS
POLY CARBONATE
APPLICATIONS• BABY FEEDING BOTTLES, MIXIE JARS• BLOOD OXYGENATORS• I.V. CANNUELA• FACTORY ROOFINGS• RAILWAYS PLATFORMS FOOFINGS/BUS STOPS• SAFETY GLAZINGS• TELEPHONE BOOTHS• OFFICE AND FACTORY PARTITIONS• COMPACT DISKS AND OPTICAL DATA STORAGE DISKS• RETURNABLE WATER AND MILK BOTTLES.
PC in AUTOMOTIVE, AUTO LIGHTING Application: Head lamp bezelMaterial: PC-unfilled
Headlamp bezels require Excellent surface finish & aestheticsGood heat resistance and be warpage freeMetallic effect and an exceptional appearance.
Injection molding.
Audi
PC in Electrical / Electronics,
TelecommunicationApplication: Mobile phone travel chargerMaterial: - PC-unfilled
A charger for a mobile phone require :- Very high aesthetic - Withstand severe drop tests - Resistant to all kind of chemical substances,like hand lotions & soaps. - Flame retardant and has to pass the pressure test at 125 ºC.
Injection Molding
Philips
PC in ELECTRICAL LIGHTING Application: Lamp holder fluorescent lamp, Material:- PC
Fluorescent lamp holders require: Tough materials with good flow to be able to mold the components
easily-PC being easy flowing and with excellent mold release.
Injection molding.
PC in Electrical / Electronics
: Application: ATM - PC-unfilled
This processing technique makes it possible to attain a cost-saving of up to 300%, when for instance changing from cast aluminium to plastic mouldings for cash dispensers (ATM’s). This molding is by made the ‘low pressure foam process’ to produce a 7,5 kg moulded automated telling machine fascia. Although the main driving force is cost reduction, issues like weight reduction, torsional stiffness, vandal resistance, paint ability to class A surface finish, dimensional stability
THERMOPLASTIC POLY ESTER(PET & PBT)
• Crystalline in nature
• Based mainly on polybutylene terephthalate. A few grades based on polyethylene and polycyclohexane dimethanol terephalate are also available
• The base resins are commercially manufactured by Esterification reaction of Terephthalic Acid and appropriate diols.
THERMO PLASTIC POLYESTER (PET & PBT)
CHARACTERISTICS • High Mechanical Strength • Excellent chemical resistance• High temperature resistance in glass filled grades• High dimensional stability• Excellent Electrical tracking resistance• Can be made flame retardant• Effect of humidity minimal • Excellent flow
THERMOPLASTIC POLYESTER (PET & PBT)
APPLICATIONS:• Connectors• TV Components• Industrial Switches/plug’s• Business machine components• Keyboard buttons• Steam irons• Cookers• Air vents• Plumbing• Auto ignition systems• Under bonnet connectors• Head lamp reflectors
* Dimensional stability for reliable performance in all conditions
*Automotive window lift mechanisms demand shock resistance over a wide temperature range,-40°C to +80°C,
*Excellent dimensional stability and strength up to the maximum environmental temperature.
*Reducing total assembly costs and weight.
Processing Technology: Injection Molding
Opel, Volvo
Application: Actuator, Gear housing window Lift
Material: PBT-GF20
PBT IN AUTOMOTIVE
•Stability and Narrow tolerances for parts close to the engine•This air-flow mass meter measures air flow speed for the motor management control system. •It has to maintain tight tolerances over the life of the vehicle and withstand the temperatures encountered close to the engine.• Exceptional dimensional stability andstrength over a wide temperature range. • The best balance of mechanical properties and good welding performance,facilitating manufacturing productivity.
Application: Air flow mass meter housing and sensor
Material: PBT-GF30
PBT IN AUTOMOTIVE
Processing Technology: Injection Molding
Opel
PBT IN AUTOMOTIVE
Application: Sensor, throttle position
Material: PBT-GF30
Application: E-Box, Fusebox
Material: PBT-GF10
Application: Compact NS Schneider Material: PBT-GF30
PBT IN : Electrical / Electronics, Power distribution & circuit protect
Application: Bobbins Schneider
Material: PBT-GF30
Processing Technology: Injection Molding. Schneider
Application: Breake Booster Valve bodies
Material: PET-GF35
•Glass fiber reinforced polyethylene terephthalate (PET) is the material of choice for automotive brake booster valve body applications.
• It provides weight, performance and cost advantages over previously used thermosets.
Processing Technology : Injection Molding
ADI BMW
PET IN AUTOMOTIVE, BREAKE /CLUTCH
PET IN AUTOMOTIVE, BREAKE /CLUTCH
Application: Tandem brake booster
Material: PET-GF35
•Glass fiber reinforced polyethylene Terephthalate (PET) is the material of choice for automotive brake booster valve body applications.
• It provides weight, performance, and cost advantages over previously used Thermosets.
Processing Technology : Injection Molding
Various
POLYACETAL (POM)
• Polymer of formaldehyde, commonly known as Polyacetal, Acetal polymer or Polyoxymethylene was first commercialised by Du pont in 1959.
• Copolymers were introduced by celanese corporation 1960 to overcome thermal stability problem at processing temp.
• Polyacetal is commercially made by polymerisation of high purity formaldehyde in rapidly stirred inert medium like dry heptane with controlled traces of water added containing phosphine and amine initiators.
POLYACETAL (POM)
CHARACTERISTICS OF POLYACETAL (POM)• High crystalline• High flammable• Resilient and good combination of stiffness and
toughness• Creep resistant- superior to polyamide• Low static and dynamic co-efficient at friction• Very high degree of precision moulding possible• Not high temp. resistant• Resistant to organic solvents upto 70 degree.
POLYACETAL (POM)POLYACETAL (POM)
APPLICATIONS OF POLYACETAL (POM)• Gears• Conveyor belt links• Sprockets and chains• Blower wheels• Cams• Fan blades• Carburettor float and bodies• Aerosol containers• Lighter bodies• LPG Cylinder caps• Shower heads
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