Trends and Innovation in Sealing Materials. Media Day 2015, Ernst Osen

Transcription

1 Trends and Innovation in Sealing Materials Media Day 2015, Ernst Osen

2 Materials for Global Requirements Technological trends on high performance parts Legal and environmental requirements Global survey of different regulations: EU Legislation (e.g.reach) TSCA GADSL Substitution of critical substances New fluids demand materials with improved compatibility Global trend towards low viscous oils due to fuel economy Next oil generation with aggressive additive packages Focus on oils with fuel admixtures and degradation products CO 2 -reduction requires low friction materials Low wear materials for long time durability Broader temperature range of use Function integration and metal replacement (2K molding)

3 Material innovation derived by market trends Social and technological progress Environment and legislation Ageing society Energy Sustainability Growing oil & gas segment Technologies to reduce energy consumption Alternative energies Medical technology Cost reduction Reduced friction Resistance against alternative fuels and lubricants Extended service life New, clean materials Low cost materials Integrated functions Intelligent materials Processability

4 Core competencies Materials Staff employed in Europe Employees Mixing facilities 240 thereof Weinheim 170 Material development 75 thereof Weinheim 23 Production of elastomer compounds In Europe 15,000 t pa Several billion seals produced per annum Production in Weinheim 8,500 t pa Supply from compounders 3,500 t pa Polymers used: NR, SBR, NBR, CR, ECO, HNBR, ACM, AEM, EPDM, FKM and FFKM Not just standard rubbers but many specialty rubbers as well! Number of specific compounds 1,810 Number of raw materials/components 1,000

5 The important role of the sealing material VMQ Very good temperature resistance up to 230 C; good chemical resistance up to 200 C EPDM For water, steam, acid and bases up to 180 C HNBR Similar to NBR, but better heat resistance up to 150 C Better rigidity FKM Good chemical and thermal resistance up to 220 C NBR Very good low temperature flexibility Good oil resistance up to120 C FFKM Very good chemical and thermal resistance up to 260 C CR, NR etc. For specific applications, e.g. boots ACM, AEM Good heat resistance Excellent oil resistance Page: 5

6 Media resistance of elastomers polar rubber non polar rubber AU, EU ACM/ AEM EVA CO/ ECO HNBR NBR XNBR CR Material EPM EPDM IIR CIIR NR IR SBR BR non polar medium Mineral oils hydrocarbons (Benzine, aromates) Medium to be sealed Synthetic lubricants polar medium Water / steam Alkohol/ glycole (brake fluid) Acids/ bases Ester/ ketone Exceptions: FFKM, FKM, FVMQ (VMQ) These materials can in general be used in polar as well as in unpolar media. not suitable suitable

7 Temperature range of elastomers Limits for low and high temperature applications The operation temperature of a seal is limited by the base polymer. In special cases the temperature ranges can be extended by compound composition. Extended low temperature Extended high temperature

8 Sealing materials for low temperature applications Simmerring e.g. 70 FKM , T g (DSC) = -30 O-Rings e.g.70 NBR 888, T g (DSC) = EPDM 281, T g (DSC) = EPDM 291, T g (DSC) = -51 Diaphragms e.g.60 FKM , Tg (DSC) = PVMQ 534, T g (DSC) = -117 Page: 8 Bellows e.g. 50 CR 879, T g (DSC) = -40 Elastomeric form parts e.g. 72 FKM , T g (DSC) = NBR , T g (DSC) = -29 Attention: For the intended use not only the low temperature flexibility is relevant, but also the media resistance and other product specific properties need to be followed.

9 New fluids demand materials with improved compatibility Influence of new lubricant generations in the case of Simmerrings Absence of lubrication Insufficient netting of the surface Occurrence of higher wear accelerated ageing higher shrinkage higher temperature on the sealing lip accelerated chemical and physical interactions Before change the fluid a compatibility test with the elastomer is required!

10 High performance materials for Process Technology Elastomer materials used for food and beverage applications need to fulfill Temperature resistance for sterilisation CIP-/SIP medium and chemical resistance Hygienic design Certification and approvals according Food and Drinking water regulations of various countries Examples of market specific materials: Fluoroprene XP 41 and 43 White EPDM and white Simriz 506 Hygienic Usit

11 Innovative material development Development of new innovative material concepts for specific customer solutions Advanced development of new materials for highest functional requirements temperature from 70 C up to +300 C aggressive lubricants and media (bio diesel, oil additive, coolant,...) service life (life time, wear) Raw material and material characterization with modern analysis methods for a detailed quality analysis of our compounds Computer Aided Compounding (CAC) to increase the efficiency in material development

12 Activities in Material Development Modeling / Simulation Lab testing Part testing Simulation of the behavior of a rod seal; comparison of two TPU compound with respect of the resetting of the sealing lip Determination of T g using different test methods and correlation with part testing in order to improve the accuracy of forecast Measurement of leakage behavior of seals on test rigs, e.g. low temperature test rig for Simmerrings Reaction time too long: leakage Studies on acidic medias (e.g. blow-by) in order to understand the deterioration mechanism and influence of multicomponents fluids Studies on various fuels and new lubrication oils Test rigs for O-Rings at low temperature: New low temperature-pu results in faster closure time of the sealing lip and therefore more reliability in usage at low temperature Long-term compression set tests for pipe couplings according to DIN requirements o static without side load o static with side load o Short-term dynamic load (shock) o Permanent dynamic load (vibration)

13 Low and high temperature elastomers NBR for extreme low temperature, very low crystallisation Temp and grease resistance New high temperature FKM materials for up to 280 C Mech. properties Hardness Shore A 70 NBR NBR Density g/cm³ 1,21 1,21 Modulus 100% N/mm² 4,9 5,3 Tensile N/mm² 12,1 12,4 Elongation at % break Tear resistance N/mm 12,9 11,3 CS 24h/100 C % 26,8 19,0 Tg (DSC) C -72,3-72,4 75 FKM FKM After Heat aging 280 C TIME 168 h 336h Mech. Prop./Change Hardness Shore 75/0 74/-1 A Modulus 100% N/mm² 16/6,7 8,1/-38,2 Tensile N/mm² 16/-29,6 14,4/-38,2 Elongation at % 205/39,5 224/ 52,4 break Vol.Change % -1-1,6 CS (ISO 815) % Page: 13

14 75 ACM 380 DF: High-performance material with higher temperature range Compression set in air at 170 C Bonding enthalpie S-S S-C C-N C-C 268 kj/mol 289 kj/mol 305 kj/mol 331 kj/mol CS at higher temperatures of HT-ACM: Reset forces remain significantly longer to ensure sealing function. Higher C-N bonding enthalpy in in combination with a new polymer design yields higher temperature resistance Innovative Sealing Solutions ZF Friedrichshafen AG Tech-Day March

15 75 ACM 380 DF: High-performance material with higher temperature range Tensile Stress relaxation in Esso Gear Oil MB 317 Material: ACM Standard & ACM HT for Simmerrings Temperature: 175 C; continuous measurement Deflexion: 20% 175 C Change in % 100,00 90,00 80,00 70,00 60,00 50,00 40,00 30,00 20,00 75 ACM 380 ACM HT 70 ACM ACM Standard 10,00 0,00 0,01 0, Time [h] Innovative Sealing Solutions ZF Friedrichshafen AG Tech-Day March

16 Thermochromic Coating: O-Rings NBR in air O-Ring coated with Thermo- color C, 24 h O-Ring coated with Thermo- color C, 6 h / 140 C, 1 h / 120 C, 17 h 1h at 140 C L*(D65) Light index 50 L*[D65] C Luft Ring 120/140/120 C Luft Ring L*[D65] Maximum temperatures on a seal can be identified and quantified with an optical device Further colors and temperature ranges available

17 Intelligent materials: Electrial conductive Materials No electrical circuit: Non-conductive rubber Electrical circuit: Conductive Rubber

18 Intelligent materials: Dielectrical Materials Tensile Stress applied to the elastomer sample can be measured on the device. Idea for the demonstrator: Measurement of the compression of a sealing

19 Intelligent materials: Dielectrical Materials