Thermoplastic Materials Engineering Plastics

MFG 355

Engineering Thermoplastics
Replace metallic parts
Strength and stiffness Retention of properties over range of temperatures Toughness to withstand incidental damage Dimensional stability
Low creep Low CTE

Withstand environmental factors (UV, O2, chemicals) Shaped easily

Engineering Thermoplastics
Compared to commodity plastics
More expensive The commodity resins are all lacking some critical property Some Engineering Thermoplastics are formed through the condensation polymerization process

Polyamides or Nylons (PA)

Polyamides or Nylons (PA)

H H H H O H O H

( N [ C ]a N
H

C [ C ]b C )n H

PA General Family Characteristics

Polarity Crystallinity Sharp meltpoint Strength Comparison of higher & lower nylon numbers

PA General Family Characteristics

Transparent (barely)cook in bag (turkey) Anti-frictionnot like PTFE but good Toughnessexcellent Fatigue resistanceexcellent Water absorptiona weakness (.2-2.5% must be dried for injection molding) Highly crystalline

Nylon 6,6
H H2N C H H C H H C H H C H H C H H C H NH2

Hexamethylenediamine (6 carbons)

Nylon 6,6
O C HO H C H H C H H C H H C H C O OH

Adipic Acid (6 carbons)

Nylon 6,6
H H2N C H H C H H C H H C H H C H H C H O NH C H C H H C H H C H H C H C OH O

Water

Nylon 6,6

O H

Nylon 6
H H H H H O C OH H2N C C C C C

Amine Group

Acid Group

Nylon 6
O H H H H H C C H2N H H H C H C H H H H H H C C N C C C C H H H H
H

Water
H O

H H C C OH O

Properties of Specific Nylon Types

Nylon 6,6 General Nylon 6 Copycat Nylon 6,10 Less water absorption Nylon 6,12 Flexibility and less water Nylon 2,2 Strength

Processing Nylon
Injection molding
Shrinkagecrystallinity.018 in/in Dry it first

Extrusion
Low melt viscosity Be careful of decomposition

Fibers
Drawing Crystallization Orientation

Nylon History
Nature of polymer bonding not understood Carothers Difunctional monomers Polymers1000 units long
Larger unitsmolecular still to eliminate water Many combinations of polyesters Trying polyamides Settling on 6,6

Control of melting point and length

Carothers death
3 weeks after patents

Tremendous success
Name
Delawear, Wacra, Norun, Nuron, Nulon, Nilon, Nylon

Aramids

Aramids
H O H C C C H C H H H C C C C N C C C H H O H C C C N H H

Acetals or Polyoxymethylenes (POM)

Acetals or Polyoxymethylenes (POM)

H
(

C H

)n

Acetal General Family Characteristics

Mechanicaldo not embrittle, good impact strength Moisturevery little (shower heads) Chemical resistancevery high, resists stains, sensitive to strong acids and bases Weatheringfair Thermal200o F Electricalgood Machininglike cutting brass Adhesionepoxy glues

Processing Acetals
Do not heat above 440o F Melt viscosity is not too dependant on temperature

Acetal Copolymer
H

O CH2 O CH2 CH2

CH2 O

Thermoplastic Polyesters (PET/PBT)

Thermoplastic Polyesters (PET/PBT)

H O H C H C H C C H C C C C H O O C H

C H

Thermoplastic Polyester General Family Characteristics

PET
Higher mechanical stiffness Strength by orienting chains not by H-bonding Get 50% crystallinity
forced by mechanical stretching

PBT
crystallizes rapidly processes faster lower overall properties

Processing PET
Shape it (film, tape, fiber, extrude, etc)
Amorphous structure

Reheat and stretch in strength direction(s) Cool to below Tg

Specific TP Polyester Types

Dacron fibermix with cotton or wool-gives permanent creases Kodel photo film Mylartransparencies, tapes PETGglycol modified, amorphous, like PVC

Polycarbonate

Polycarbonate
H O C O C C H C H C C H H H C H C H C H H C C H C H H C C C H

)n

History
Solvent resistance (DuPont) GE-Lexan Properties
Polar Stiffness of backbone Long repeat unit

Properties
Solvent sensitivitypoor but nice for joining Clearexcept for UV yellowing, slight crystallinity Hard Ductilenailed, sawed, drawn, punched, sheared, drilled Toughhelmets, light covers, windows, roadside signs, bullet proof shields Dimensional stabilitylow creep Electrical resistancegood but not fantastic Machininggood

Acrylics (PAN, PMMA)

Acrylics (PAN, PMMA)

H H H C H

(C
H

C C O

)n
O

)n

C H

Properties
Color (transparency)20 years w/ <10% change Weatheringbest Mechanical propertiesaverage except for impact (brittle) Chemicalchlorinated solvents attack it, acetone gives it cracks Electricalgood

Uses
Signs Counter topsCorian Decorative pieces Floor waxes Paint, fingernail polishes Contact lenses, glasses

Processing
Casting (sheets)syrup Injection moldinggood Thermoformingok but brittle Machiningsimilar to wood

Flouropolymers (PTFE, FEP, PFA)

Flouropolymers (PTFE, FEP, PFA)

F
(

F C F
)n

C F

History of Discovery
Chambers plant
Making Freon Gas cylinder

Properties
Most are strengthened by the tight bond between the Fluorine and the Carbon atoms
Slippery (anti-stick surfaces) Chemical inertness High temperature melting Non-flammable High electrical resistance Very dense2.13-2.2 (high melt viscosity)

Uses
O-rings Non-stick surfaces Insulation-electrical Lubricant Coatings Gears

Processing
Not processable by extrusion or injection molding
Sintering
Put in approx shape and heat620o F Similar to processing powdered metals Fusion

Ram extrusion
Compaction Rods and tubes

Calendaring

Very poor adhesion

High Performance Thermoplastics

PPO Properties
Thermal stabilityexcellent (650o F) High HDT = 375o F Good cold properties (-275o F) Low water absorption Low heat expansion Good solvent resistance, but can be solvent welded

PPO uses
Used to replace stainless steel for surgical equipment Replace thermosets Pump housings Valve components Video terminal housings

Polyaryletherketones (PEEK, PEK, and Others)

Polyaryletherketones (PEEK, PEK, and Others)

H C C C H C H H C C O C C C H H H H C C C H O C C C C H H C C C H

Ether Linkage

Ketone Linkage

Polysulfones (PSU and PES)

Polysulfones (PSU and PES)

H C C C H C H H C C H O S O C C H H C C H H C C H C H C C C O C H H C C C C H H C H C C O

Properties
Resistant to oils Heat stability (300o F) Creep resistance SO2 group adds stiffness More dimensionally stable than PPO Toughnessgood

Uses
Hot water pipes Coffee pots Dishwasher components Automobile applications near engines Compete with thermosets, but can be injection molded

Thermoplastic Polyimides (PI and PAI)

Thermoplastic Polyimides (PI and PAI)

H C O C C N C H C H C O C

(C

( )
n

)
H

Properties
Very stiff Highest thermal stability PI cannot be melted or melt processed PAI can be (Torlon) PI is sintered (Vespel) PI film is cast as monomers and heated to polymerize (Kapton)

Uses
PI is used in circuit boards High temperature parts Low friction bearings, sliding parts Gears

Cellulosics

Cellulosics
Nitrocellulose
Gun cotton

Cellulose nitrate
Lacquers and plastics

Properties

Fire
Fire Hard
Plasticized with camphor

Water repellent

Types of Cellulosics
Rayon
Viscose process

Cellophane Methyl cellulose

Filler Edible

Thank You

Nylon History
Carothers
IowaBS IllinoisPhD HarvardTeach DuPontbasic research

Polyphenylenes (PPE, PPO, and PPS)

H H H C C H C H H C C C C C H H H OH

PPO