How properties of thermoplastics are affected by processing.

Transcription

1 How properties of thermoplastics are affected by processing. Nick Barron Global Industry Manager Oil & Gas, Röchling 2nd June 2016 Material processing and its effects - NKF 1

2 Presentation Outline Who are Röchling & Astrup? Why plastics? Polymers and moisture corrosion avoidance. Introduction to material processing types. Processing and effects on material properties Conclusion 2nd June 2016 Material processing and its effects - NKF 2

3 Who are Röchling: Global provider of thermoplastic and composite material solutions. 77 locations in 22 countries Established 1822 Privately owned Annual sales of 1.6 billion 8,400 employees Quality Management Systems to: ISO 9001, ISO 13485, AS9100 ~100 years experience in the processing of thermoplastics and composites. Let Röchling help you meet the most demanding operational requirements. 2nd June 2016 Material processing and its effects - NKF 3

4 Röchling, available across the globe: Oil & Gas supply chain Motorsport Aerospace & Railway Electrical & Electronics Industry Chemical Industry Mechanical Engineering Food Processing Renewable Energy Medical technology Paper industry Marine 2nd June 2016 Material processing and its effects - NKF 4

5 Astrup: Norway's leading supplier of metals and plastics. Established 1857 Privately owned 157 employees Annual turnover of NOK 772 million 6 Sales offices across Norway; (Oslo, Bergen, Skien, Stavanger, Ålesund & Trondheim. 2nd June 2016 Material processing and its effects - NKF 5

6 Why use polymers? Weight reduction. Noise reduction. Corrosion resistant. Naturally insulating Low friction Cost. However, choosing the best material and the optimum production process is key to ensure the part operates as intended. 2nd June 2016 Material processing and its effects - NKF 6

7 Moisture and plastics Chemical Resistance of Specialty Thermoplastics: Chemical Resistance, Volume 3 2nd June 2016 Material processing and its effects - NKF 7

8 Moisture and plastics Why don t plastics corrode like metals? 2nd June 2016 Material processing and its effects - NKF 8

9 Moisture and plastics Durostone fasteners Glass fibre thermoset materials do not corrode like metallic fasteners and offer strength benefits over thermoplastic fasteners. Internal tests have shown maintenance of properties in conditions analogous to those found subsea environments. Contact for more information 2nd June 2016 Material processing and its effects - NKF 9

10 When selecting polymers... Thermal and mechanical considerations UV ATEX/Flame retardant Finished part production: - Injection moulding - Semi-finished material production and machining? Extruded material Cast material Compression moulded material - Additive manufacturing (3D printing) which key points do you consider? 2nd June 2016 Material processing and its effects - NKF 10

11 Polymers processing techniques Injection moulded material Hot melt material is injected into a cold tool under high pressure. The injected material freezes to produce the finished shape. Low viscosity grades required to fill mould tools. Produces finished part in 1 shot. Cost efficient for large quantities of parts. By ariel cornejo - Own work, CC BY-SA 4.0, Extruded material High viscosity polymer is heated and forced out of a die (in to sheets, tubes, rods and custom profiles). Slow cooling of material leads to lower material stress than IM. Secondary annealing further reduces material stress. Machining of material required to give finished part. 2nd June 2016 Material processing and its effects - NKF 11

12 Polymers processing techniques Compression moulded material Material is heated under pressure in mould. Leads to very low stress material due to slow production times. Material holds tighter tolerances than extruded material. Additive manufacturing More commonly known as 3D-printing, various types exist including SLS (selective laser sintering) or FFF (fused filament fabrication). Molten plastic (FFF) is deposited out of a nozzle to give the finished part. For SLS, powders are fused in layers to complete the part. 2nd June 2016 Material processing and its effects - NKF 12

13 Polymer processing and its effect Polymer processing techniques can have a significant affect on the materials mechanical properties. Röchling Röchling Röchling Extruded Material Compression Moulded Injection Moulded 2nd June 2016 Material processing and its effects - NKF 13

14 The effect of processing on material properties Polymer processing techniques have a significant affect on the materials mechanical properties: 30% carbon fibre filled PEEK Extrusion (SustaPEEK CF30) E-Modulus (Mpa) Compression moulding (SustaPEEK CM CF30) Injection moulding Tensile strength (Mpa) Extruded Compression moulded Injection moulded 2nd June 2016 Material processing and its effects - NKF 14 0 Extruded Compression moulded Injection moulded

15 The effect of processing on material properties Polymer processing techniques have a significant affect on the materials mechanical properties: 30% carbon fibre filled PEEK Extrusion (SustaPEEK CF30) Compression moulding (SustaPEEK CM CF30) Impact properties Injection moulding Extruded Compression moulded Injection moulded Charpy notched impact strength (kj m2) Elongation at break (%) 2nd June 2016 Material processing and its effects - NKF 15

16 Mpa Mpa Additive manufacturing 30% Fibre filled nylon 12 (PA 12) [SustaMID 12 GF30] Extruded vs. 3D printed material E-Modulus (Mpa) Yield Stress Nylon 12 (30% glass) x-direction y-direction z-direction 0 Nylon 12 (30% glass) x-direction y-direction z-direction 2nd June 2016 Material processing and its effects - NKF 16

17 Additive manufacturing 30% Fibre filled nylon 12 (PA 12) [SustaMID 12 GF30] Extruded vs. 3D printed material Impact properties Nylon 12 (30% glass) x-direction y-direction z-direction Charpy notched impact strength (kj m2) Elongation at break (%) 2nd June 2016 Material processing and its effects - NKF 17

18 Additive manufacturing vs. extrusion 30% Fibre filled nylon 12 (PA 12) [SustaMID 12 GF30] Extruded vs. 3D printed material Röchling Röchling x Röchling x Röchling y y z Röchling Röchling z 2nd June 2016 Material processing and its effects - NKF 18

19 Conclusion: Thermoplastic and thermoset materials are naturally corrosion resistant materials. Non-metallic materials can offer cost savings (no need for anode), weight reduction, maintenance free and corrosion resistant. Composite materials (glass fibre) offer the highest mechanical properties with E-modulus >30,000 Mpa and show no degradation in mechanical properties from salt water immersion. One such application could be the use of thermoplastic or thermoset fasteners in certain applications. 2nd June 2016 Material processing and its effects - NKF 19

20 Röchling, a leading, global processor & machinist of thermoplastic and thermoset (composite) materials, with >400 years experience to call upon. We can offer you the optimum material selection solution from cryogenic to high temperature (+500 C) Thank you for listening. Dr. Nick Barron Global Industry Manager Oil & Gas nbarron@sustaplast.de PE, PP, POM, PA (nylon), PET, PK, PVDF, PTFE, PEEK, PEI, PPS, PPSU, PES, PSU, Epoxy, Polyester.