EMS-Grivory Material Technology. Metal Replacement With Engineering Polyamides. Ron Hamilton [Consultant] EMS-Grivory UK

Transcription

1 EMS-Grivory Material Technology Metal Replacement With Engineering Polyamides Ron Hamilton [Consultant] EMS-Grivory UK Gjorvik 19 th September, 2013

2 BACKGROUND FACTS Ex-EMS-Grivory UK Marketing [12 Years] handling direct sales to Scandinavia. Now, working as consultant in a sales support role. EMS UK Grivory UK is subsidiary of EMS Chemie AG, a Swiss-based, global producer of polyamide polymers and compounds. Traditionally, Grilon Nylon 6 & Nylon 6.6, together with Grilamid Nylon 12 Today, EMS have developed a comprehensive range of partially-aromatic polyamides called Grivory GV & Grivory HT. These offer improved stiffness, strength and thermal behaviour. Together with excellent long term creep, such materials provide low cost and low weight alternatives to die cast alloys eg aluminium, magnesium and brass.

3 High Performance Polyamides for Metal Replacement

4 1.8 t

5 Thread Strength is Comparable to Alu Die-Cast Injection moulded thread Steel screw M8 24 mm screw depth max. Load 3'000 kg

6 Polyamide Specialities for Metal Replacement Grivory GV & HT High Strength Polyamides Comparison to Metals Successful Applications in - Automotive - Industry - Consumer Products

7 Fibre Reinforced, Partial Aromatic Polyamides Grivory GV High stiffness & strength also in warm & humid climate Low tendency to creep High dimensional stability Grivory HT1 / HT2 High stiffness & strength also at high temperatures Excellent chemical and hot water resistance Flame retardant grades available

8 Grivory remains stiff after moisture absorption E-Modulus [GPa, 23 C] dry conditioned * 50% glass-fibre content 5% < 5% % 30% 10 8 PA 6 PA 66 Grivory GV Grivory HT1 * normal climate (23 C / 50% rel. humidity)

9 Grivory GV & HT High Creep Resistance Elongation [%] at 40 MPa ISO 899 / 23 C / conditioned HTV-5H1 GV-5H PA 66 GF Time [ h ]

10 Grivory High Dimensional Stability 6 5 Water Absorption [%] plate, 3 mm, 23 C Storage Time [days] HTV-5H1 HT2V-5H GV-5H PA6 GF50

11 Grivory HT High Stiffness at High Temperatures 20 Tensile-E-Modulus [GPa] 60% 40% ISO 527/ dry 25% 50% C 80 C 120 C 5 0 PA66 GF50 PA46 GF50 HTV-5H1 HT2V-5H

12 New Products for Metal Replacement Grivory GVX extremely stiff & strong / up to 70% glass-fibre reinforced very low warpage Grivory GVL & HTVL long-fibre reinforced improved energy absorption & heat distortion reduced tendency to creep Grivory HT3 new high-temperature PA low water absorption / improved hydrolyses resistance extrusion grades available

13 Polyamide Specialities for Metal Replacement Grivory GV & HT High Strength Polyamides Comparison to Metals Successful Applications in - Automotive - Industry - Consumer Products

14 Grivory in Direct Comparison to Die-Cast Metals Die-Cast Alloys Grivory GV-5H Grivory HTV-5H1 Zinc GD Zn Al4 Cu1 Aluminium GD Al Si9 Cu3 Tensile tests between -20 and 120 C Impact- and notched impact tests at -30 and 23 C Creep tests Fatigue tests

15 Comparison of Densities 10 Density [g/cm 3 ] Brass 7.9 Steel 6.7 Zinc Alu 2.1 PTFE Mg 0.9 PE 1.47 Metal Polymers Grivory GV / HTV

16 Strength of Grivory Similar as Die-Cast Metals Tensile Strength [MPa] ISO 527 / dry 23 C 80 C 120 C Zinc-DC Alu-DC Grivory GV-5H Grivory HTV-5H1

17 Die-Cast Metals are Stiffer than Grivory Tensile-E-Modulus [GPa] 23 C 80 C 120 C ISO 527 / dry Zinc-DC Alu-DC Grivory GV-5H Grivory HTV-5H1

18 Zinc Die-cast creeps more than Grivory Elongation [%] Grivory GV-5H Grivory HTV-5H1 100 MPa / 23 C / cond., ISO 899 Grivory GV-5H Grivory HTV-5H1 0.6 Zink-DG Zinc-DC Alu-DG Alu-DC Time [h]

19 Up to 50% Cost Reduction by Metal Replacement Key factors: no post treatment deflashing, machining, cutting of threads no surface treatment colouring, corrosion protection easier handling during transport, storage, assembling longer tool life factor of 4-5 against alu die-cast

20 Cost Example: Alu Die-Cast vs. Grivory 4 Manufacturing cost per part [CHF] 3 42% Cost reduction Alu-diecasting Grivory GV Material Tooling Production Post-Treatment

21 Polyamide Specialities for Metal Replacement Grivory GV & HT High Strength Polyamides Comparison to Metals Successful Applications in - Automotive - Industry - Consumer Products

22 Automotive Applications with Grivory GV wood trim substrate functional carrier housing for airbag middle arm rest luggage boot handle Interior air intake grill Exterior wiper system components Powertrain air collector Ref: Audi door handle with carrier seat adjustment mechanism head lamp fixation air-brake system components stabilizer link-arm steering lock housing wing mirror parts

23 Functional Carrier out of Grivory GV Replacement of magnesium die-cast with 40% cost saving High stiffness & strength in warm humid climate Low warpage & close tolerances (< 0.1mm)

24 Steering Lock Housings out of Grivory GV Replacement of alu die-cast up to 50% cost saving Close tolerances and low warpage EMS support on tool design (Moldflow)

25 Cupholder & Cover out of Grivory GVX Low deformation High dimensional stability Good surface quality

26 Bracket for Convertible Roof out of Grivory GVL High stiffness & strength High crash resistance SPE Automotive Award 2010

27 Fibre-Felt Structure of Grivory GVL Part Short glass fibre Long glass fibre

28 Wind Screen Wiper console of Grivory GV & GC Replacement of alu die-cast with 30% cost saving Cost advantage by 3-Component Moulding previous solution Grivory GV-5H / Grivory GC-4H

29 Wind Screen Wiper console of Grivory GV & GC Crimp joint with steel pipe Bearing out of Grivory GC-4H Dampening element out of TPE

30 Automotive Applications with Grivory HT functional carrier middle arm rest bracket fuel connector throttle body clutch sleeve cylinder Ref: Audi Interior Exterior Powertrain water pump components head lamp housing intercooler housing valve control flap engine control flaps

31 Bosch Water Pump Housings out of Grivory HT Resistance against cooling water Laser-welding with PA66 CAE-Support by EMS

32 Bosch Throttle Body out of Grivory HT1 Working temperature up to 180 C High dimensional stability Assembly injection moulding with PPS

33 Frame for Curve Light out of Grivory HT1 Alternative to Alu with 30% cost saving High temperature resistance Fatigue strength & close tolerances Slide bearing of Grivory HT PTFE modified

34 Central Clutch Cylinder out of Grivory HT1 Replacement of alu die-cast with 30% cost saving High stiffness and strength up to 170 C Excellent surface quality (inside)

35 Source: PSA Gear Box Control Plate out of Grivory HT1 Replacement of alu die-cast with 40% cost saving High dimensional stability CAE support on part design by EMS

36 Water meter housing out of Grivory GV & HT FWA Substitution of brass > 50% cost reduction Potable water approvals Burst pressure optimization by OVALIX (EMS-Patent)

37 Water Filter out of Grivory GV & Grilamid TR Cold water until 16 bar Potable water approval Chemical resistance Colourability

38 Water Distributor for Shower out Grilamid FWA Reduced number of parts (10 2) 90% weight saving ( g) 65% cost savings High elongation at break (quick-connector) Water temperature up to 60 C

39 Pneumatic Valve Block out of Grivory HT Substitution of alu die-cast Chemical resistance Close tolerances High surface quality

40 Gear Box for Actuator out of Grivory GV & HT HTV-3H1 HTV-3H1 grey GV-4H grey Good oil resistance Low water absorption Works between 0 C - 50 C up to 95% humidity

41 Coffee Machine Parts out of Grivory HT FWA Hydrolysis resistance Low creep Chemical resistance (descaler) Food approvals

42 Spring Housing for Hinges out of Grivory HT High creep resistance High strength Low warp

43 TV Wall Bracket out of Grivory GV High strength Low creep Approved until 15 kg / 10 years guarantee

44 Airport Chairs out of Grivory GVX First full plastic seat for airports Low deflection at 200kg High surface quality

45 Desk Lamp out of Grivory GV High stiffness Excellent surface Very good flow properties (500 mm) at low wall thickness

46 Crutch out of Grivory GVX Filigree lightweight structure 120 kg usage load 1 Mio load cycles at 70 kg Excellent surface

47 External Bone Fixation out of Grivory GV Replacement of of stainless steel 60% cost saving 80% weight reduction

48 Our Services for Metal Replacement FEASIBILITY STUDIES - Design concepts - Cost comparison to metal - Tech-Days MATERIAL SELECTION - Comparative tests - Material modifications CAE-SERVICE - Part optimization (FEM) - Tool design (Moldflow)

49 Our Services for Metal Replacement PROTOTYPING - Rapid Prototyping - Manufacturing of Prototypes incl. tools - Modification & Sampling of die-cast tools - Application specific testing PRODUCTION - Process and tool optimization - On-site Support - Customer training

50 Metal replacement with Grivory Grivory GV & HT proved for years in metal replacement high cost & weight saving potential Main features High stiffness & strength also in warm humid climates Excellent resistance to chemicals and hot water Low tendency to creep & high dimensional stability

51 Your Development Partner for Metal Replacement THANK YOU!