For Lightweight Aerospace Components

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1 Aerospace engineers require lightweight materials that provide processing flexibility, reduce manufacturing costs, and provide durability in harsh environments. polymers have successfully displaced metals, traditional composites and other plastics in a growing number of aerospace applications because they are exceptionally strong, inert, and inherently flame retardant, and can be easily fabricated into tight tolerance parts. polymers have been officially qualified by many aircraft manufacturers and can also be supplied to the military specification MIL-P Several new polymer grades and compounds are available to maximize mechanical properties and improve moldability. In addition, Victrex has introduced new APTIV films and VICOTE Coatings based on polymer to optimize consistency in a range of product forms. KEY PROPERTIES Excellent High Temperature Performance - Continuous Use Temperature (CUT) of 26 C (5 F) - Heat Deflection Temperature (HDT) Unfilled materials: 152ºC (36ºF) Carbon/glass fiber reinforced materials: 335ºC (635ºF) - No loss in tensile strength after aging at 2 C (392 F) for one year Excellent Fatigue Performance Excellent Wear Resistance Excellent Chemical Resistance - Chemically very stable and resistant to attack - Long term property retention in jet fuel and hydraulic fluids Excellent Hydrolysis Resistance - Stable with long-term exposure to hot/humid conditions Excellent Fire, Smoke and Toxicity Performance - 45G is UL94 V- rated at 1.5 mm - Low smoke and toxic gas emissions Excellent Electrical Properties PERFORMANCE Stability at Elevated Temperatures Many aerospace components must endure continuous long term exposure to elevated temperatures. polymer is extremely stable when tested against other commonly known high heat thermoplastics. Figure 1: Relative Thermal Index (RTI) Values as Measured by UL 746B Temperature ( C ) PA6/6 PPA PPS PES PET PAI For Lightweight Aerospace Components

2 Superior Performance... High Temperature Resistance Due to the semi-crystalline structure of polymer mechanical properties are maintained well past the glass transition temperature. Figure 2: Yield Strength as a Function of Temperature for Polymers Tensile Yield Strength / MPa G 45CA3 45GL Temperature / C Flammability polymer performs exceptionally well in respect to flammability. 45G is UL94 V- rated at 1.5 mm and has a Limiting Oxygen Index of 35% at 3.2 mm thickness and 24% at.4 mm thickness. These flammability characteristics are inherent in the material and are achieved without the inclusion of any flame retardant materials such as halogen-based additives. In tests to measure smoke produced by the combustion of plastic materials, the data shows that unfilled polymer has the lowest value of specific optical density of all the materials tested. Figure 3: Forced Combustion Chamber Smoke Results for a Range of Polymers Coefficient of Thermal Expansion The inclusion of fillers into polymer results in a reduction in the coefficient of expansion to a level where it is comparable to metals, thus allowing direct replacement of metal components with polymer-based components without any risks arising due to differential expansion. Figure 4: Coefficient of Linear Expansion in Flow Direction of Polymer-Based Materials in Comparison with Other Common Aerospace Materials CTE / µm m -1 C Composite UF* 9CA5 *Unidirectional Fibers 45CA3 45GL3 45G 775-T6 AISI 413 Aluminum Steel A-55 Magnesium Titanium ZK6A-T5 Strength polymer has high specific strength compared to metals. Reinforcing with chopped glass or carbon fibers yields strength-to-weight ratios that meet or exceed those of common aerospace materials. Continuous fiber reinforced composites made with a polymer matrix have significantly higher strength and stiffness. Figure 5: Specific Strength of Polymer-Based Materials in Comparison with Other Common Aerospace Materials CTE / 1-6 in in -1 F -1 Specific Optical Density (Dg) has the lowest smoke density in NBS smoke chamber test meets compounds OSU 65/65 meetheat OSUof 65/65 release heat release UL94-VO V-O flame rating at mm inches Limiting oxygen index of 35% at mminches ABS Polyester laminate PVC Polystyrene Polysulphone Polycarbonate PTFE Phenolic PEI 45G Specific Strength / MPa g -1 cm Composite UF* 9HMF4 * Unidirectional Fibers 45CA3 775-T6 AISI 413 Aluminum Steel A-55 Titanium Magnesium ZK6A-T Specific Strength / psi lb -1 in 3 Toxic Gas Emission polymer produces very little toxic gases when combusted. It produces mainly carbon dioxide and carbon monoxide upon pyrolysis. 45G has a toxicity index of.22 (MOD NES 713) with no acid gases detected. 1 Polymer For Lightweight Aerospace Components Chemical Resistance polymer has exceptional resistance to a wide range of acids, bases and hydrocarbons including jet fuel and hydraulic fluid. Soaking compounds in 7 C (158 F) hydraulic fluid for 1, hours led to less than a 5% change in nominal properties of tensile strength, tensile modulus and tensile elongation.

3 Interior Applications... ELECTRIC WIRE BUNDLE AND TUBING CLAMPS polymer has been coupled with a proprietary silicone overmolding process to produce a range of wiring, tubing clamps and stand-offs that deliver significant weight and cost savings on the new Boeing 787 aircraft. Key Benefits: Weight is reduced versus aluminum Part count is reduced by consolidation Material is completely non-corrosive and non-conductive for use throughout un-pressurized zones. Examples of Wiring and Cable Clamps made from polymer IMPELLER BLADES polymer has been used to replace metal propellers and impellers in a variety of aerospace devices including oil cooling systems and ventilation system fans used for low pressure air delivery in helicopters. They can be designed to weigh much less than metal components, have less inertia and reduce the horsepower requirements of the motors used to spin the blades. Environmental Control System Impeller made from polymer AIRCRAFT DOOR HANDLES Weight reduction was paramount when developing the Airbus A38. This included door handle systems. polymer was the only material to survive the Airbus test program for door handles. Components are injection molded and have complex geometries with numerous ribbing and long flow paths. Examples of Door Handles made from polymer INSULATION COVER FILMS Insulation films have evolved significantly over the past decade driven by more demanding FAA regulations and weight reduction initiatives. Over the past two years, Victrex has worked closely with Aircraft Insulation Lining the fuselage airframe makers and film laminators to supply very thin APTIV film for a new class of lightweight insulation film coverings offering 5-6% weight reduction versus PVF (polyvinylfluoride). COMPLEMENTARY SYSTEMS Composite Fasteners Airplane structures made of lightweight composite materials are becoming standard for new airplane developments. However, joining these structures is too often done with standard metal fastening systems that add unwanted weight. Now a composite material made of continuous fiber reinforced polymer is filling the gap with truly lightweight fastening systems, bolts, nuts, inserts and brackets. These composites have a static strength comparable to high tech aluminum alloys and fatigue properties of titanium alloys. They are compatible with the aircraft s composite structure in respect to E-modulus, resonance performance and corrosion issues. Cable Ties Used for bundling and securing wires and cables to the airframe. Low moisture absorption of polymer ensures the dimensional integrity of the ties so they will not swell and damage wire insulation. Composites Fasteners made with polymer Cable Ties made with polymer Cable Harnesses Braided cable harnesses made with monofilaments are preferred over metallic braided harnesses due to superior chafe resistance, resistance to heat aging, mechanical strength, electrical properties and tribological properties. Pipes and Convoluted Tubing Convoluted tubing made with polymer offers a solid, yet flexible barrier to chemicals and moisture with lighter weight and better crush resistance. Pipes can be extruded in a range of sizes and material formulations for specific applications. Polymer For Lightweight Aerospace Components 2

4 New Products... HIGH FLOW GRADES High flow grades permit higher levels of reinforcing fibers to be incorporated without any loss of processability. Table 1 shows typical properties of a selection of high flow ( 9 grades) and standard flow materials. Table 1: Typical Properties for Compounds Notched Spiral Material Tensile Tensile Flexural Strength Modulus Modulus Izod Impact Strength Flow Length (MPa) (GPa) (GPa) (kj m -2 ) (mm) ISO 527 ISO 527 ISO 178 ISO 18/A Victrex Glass Filled 9GL GL GL GL Carbon Filled 9HMF HMF CA CA CA WEAR GRADES Victrex has introduced new wear grades for improved lubricity and T-Series polymer for improved wear performance at elevated temperatures. APTIV FILMS APTIV films are among the most versatile and high performing thermoplastic films. They provide all of the properties of polymer in a flexible film format. Films can be supplied in thicknesses from 6 to 75 microns and up to 1.5 meters wide. Insulation Cover Films and Tapes made with APTIV film APTIV film has been successfully thermoformed into parts and trays with a range of thicknesses to provide a strong, lightweight part that has the possibility to replace metal components in aerospace applications. Secondary processes to produce complex structures include thermoforming, lamination, heat sealing, welding and metallization. Applications in commercial aerospace include: Laminate structure for thermal-acoustic insulation to provide an excellent moisture barrier and very low weight. Coverlay film to mechanically protect a thin fire barrier where the low smoke and low toxic gas generation of the film provide excellent system performance in burn-through tests. VICOTE COATINGS VICOTE Coatings are based on polymer to give enhanced wear, scratch, abrasion, high heat and chemical resistance in demanding applications. All the properties of polymer are available in a thin surface layer to protect metal substrates. VICOTE Coatings have some of the industry s lowest VOCs of any commercially available coating. The majority of grades are FDA and RoHS compliant. COMPOSITES In addition to standard grades for injection molding or extrusion, polymer can be used as a matrix for thermoplastic composite prepregs made of carbon, glass, or aramid continuous fibers. Its outstanding properties make it an excellent substitute for metals and thermoset composites. Several product forms are available: Braid Consolidated fabrics Dry fabrics Long fiber flakes Long fiber pellets Multiaxial fabrics Tow Unidirectional tape UD sheet Conventional sprayer used to apply VICOTE Coating Carbon Fabric made with polymer UD Tape made with polymer Polymer For Lightweight Aerospace Components 3

5 Exterior Applications... RADOMES polymer has been injection molded into high tolerance radomes up to 35cm (14 in) in diameter. It offers the following benefits: Superior rain resistance Strength Consistent electrical properties over extreme temperature ranges when compared to other radome materials. Radome materials must also withstand severe thermal shock and temperature extremes without cracking or deforming. polymer is very dimensionally stable over a broad range of temperatures. It withstands severe temperature fluctuations due to its low moisture absorption, ductility and excellent fatigue properties. MANHOLE COVERS Fuel tank manhole covers on the Airbus A38 are external non-structural parts for which the critical issues are weight, chemical resistance and fuel resistance. polymer was selected based on: Weight reduction Ease of manufacture Chemical resistance Dimensional stability over a broad temperature range Low moisture absorption Low coefficient of expansion A38 HTP Manhole Cover made of polymer Radome made from polymer LANDING GEAR HUBCAPS New Boeing 777 aircraft will be equipped with the Crane Tire and Brake Monitoring System which includes active pressure sensors and transmission of real-time data to the cockpit. The system specifies in the hubcap because of its high temperature performance, mechanical strength, low coefficient of thermal expansion, and chemical resistance. Aircraft landing gear must survive some of the most extreme environments and loading conditions including: Temperatures -54 C (65 F); at altitude and over 2 C (392 F) during braking Repeated hard landings Impacts from flying debris Chemical exposure to jet fuel, hydraulic fluid, and de-icing solution Ozone exposure PYLON FAIRINGS polymer has been qualified for use in a pylon fairing application. This large part was previously made of aluminum and is fixed on the lower door of the thrust reverser and interfaces with the aircraft pylon. The reasons for switchng to polymer were mass and cost reduction. The polymer qualified for the following reasons: Heat deflection temperature of 335ºC (635ºF) Mechanical properties that met requirements Good impact resistance Suitable viscosity for manufacturing the part Pylon Fairing made from polymer Boeing 777 Hubcap made with polymer Polymer For Lightweight Aerospace Components 4

6 PROPERTIES OF 45G, 15GL3 AND 15CA3 Property Conditions Test Method Units 45G 15GL3 15CA3 (unfilled) (glass filled) (carbon filled) GENERAL Density Crystalline ISO 1183 gcm Amorphous ISO Water Absorption 24h, 23º C ISO 62-1 % (3.2 mm thick tensile bar) Equilibrium, 23ºC MECHANICAL Tensile Strength Break, 23ºC (Yield*) ISO 527 MPa 1* Break, 125ºC (Yield*) 5* Break, 225ºC (Yield*) 13* 55 7 Tensile Elongation Break, 23ºC ISO 527 % Flexural Strength 23ºC ISO178 MPa Flexural Modulus 23ºC ISO 178 GPa Izod Impact Strength.25 mm notch, 23ºC ISO 18/A kjm Unnotched, 23ºC ISO 18/U no break 5 4 THERMAL Melting Point ISO ºC Glass Transition (Tg) ISO ºC Specific Heat Capacity 23ºC DSC kjkg -1 ºC Coefficient of Thermal Expansion Along flow below Tg ISO ppm ºC Average below Tg Along flow above Tg Average above Tg Heat Deflection Temperature 1.8 MPa ISO 75A-f ºC Thermal Conductivity 23ºC ISO/CD Wm -1 ºC Continuous Use Temperature Electrical UL 746B ºC Mechanical w/o impact Mechanical w/impact FIRE, SMOKE AND TOXICITY Flammability Rating UL94 n/a 1.5 mm mm mm Limiting Oxygen Index.4 mm thickness ISO 4289 %O mm thickness 35 ELECTRICAL Dielectric Strength 2.5 mm thickness IEC kvmm µm thickness 19 Loss Tangent 23ºC, 1MHz IEC 625 n/a.3.4 Dielectric Constant 5Hz, -15ºC IEC 625 n/a Hz, 2ºC IEC Volume Resistivity 23 C IEC 693/ASTM D4496 Ωcm World Headquarters Victrex plc Hillhouse International Thornton Cleveleys Lancashire FY5 4QD United Kingdom Tel: + (44) Fax: + (44) victrexplc@victrex.com Americas Victrex USA Inc 3 Conshohocken State Road Suite 12 West Conshohocken, PA USA Tel: + (1) 8- Tel: + (1) Fax: + (1) americas@victrex.com Europe Victrex Europa GmbH Langgasse Hofheim/Ts. Germany Tel: + (49) Fax: + (49) eurosales@victrex.com Asia Pacific Victrex Japan Inc Hanai Building 6F Shiba-Kouen Minato-ku Tokyo Japan Tel: + (81) Fax: + (81) japansales@victrex.com Asia Pacific Victrex High Performance Materials (Shanghai) Co Ltd Part B Building G No Zhuanxing Road Xinzhuang Industry Park Shanghai 2118 China Tel: + (86) Fax: + (86) scsales@victrex.com Victrex USA 59/1.5m PLC BELIEVES THAT THE INFORMATION CONTAINED IN THIS BROCHURE IS AN ACCURATE DESCRIPTION OF THE TYPICAL CHARACTERISTICS AND/OR USES OF THE PRODUCT OR PRODUCTS, BUT IT IS THE CUSTOMER'S RESPONSIBILITY TO THOROUGHLY TEST THE PRODUCT IN EACH SPECIFIC APPLICATION TO DETERMINE ITS PERFORMANCE, EFFICACY AND SAFETY FOR EACH END-USE PRODUCT, DEVICE OR OTHER APPLICATION. SUGGESTIONS OF USES SHOULD NOT BE TAKEN AS INDUCEMENTS TO INFRINGE ANY PARTICULAR PATENT. THE INFORMATION AND DATA CONTAINED HEREIN ARE BASED ON INFORMATION WE BELIEVE RELIABLE. MENTION OF A PRODUCT IN THIS DOCUMENTATION IS NOT A GUARANTEE OF AVAILABILITY. PLC RESERVES THE RIGHT TO MODIFY PRODUCTS, SPECIFICATIONS AND/OR PACKAGING AS PART OF A CONTINUOUS PROGRAM OF PRODUCT DEVELOPMENT. IS A REGISTERED TRADEMARK OF MANUFACTURING LIMITED., APTIV, -ESD, T-SERIES, -HT AND ST ARE TRADEMARKS OF PLC. VICOTE IS A REGISTERED TRADEMARK OF PLC. THE USE OF TM ON THE OTHER MARKS IS ACCEPTABLE, IRRESPECTIVE OF WHETHER PLC MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, A WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR OF INTELLECTUAL PROPERTY NON-INFRINGEMENT, INCLUDING, BUT NOT LIMITED TO PATENT NON-INFRINGEMENT, WHICH ARE EXPRESSLY DISCLAIMED, WHETHER EXPRESS OR IMPLIED, IN FACT OR BY LAW. FURTHER, PLC MAKES NO WARRANTY TO YOUR CUSTOMERS OR AGENTS, AND HAS NOT AUTHORIZED ANYONE TO MAKE ANY REPRESENTATION OR WARRANTY OTHER THAN AS PROVIDED ABOVE. PLC SHALL IN NO EVENT BE LIABLE FOR ANY GENERAL, INDIRECT, SPECIAL, CONSEQUENTIAL, PUNITIVE, INCIDENTAL OR SIMILAR DAMAGES, INCLUDING WITHOUT LIMITATION, DAMAGES FOR HARM TO BUSINESS, LOST PROFITS OR LOST SAVINGS, EVEN IF HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, REGARDLESS OF THE FORM OF ACTION.

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