DuPont Superstructural Web Seminar PUSHING BACK THE BARRIERS TO METAL REPLACEMENT February 28, 2006
DuPont Superstructural Web Seminar PUSHING BACK THE BARRIERS TO METAL REPLACEMENT The information and suggestions provided in this on-line seminar are based on data believed to be reliable, but the DuPont Company makes no warranties express or implied as to their accuracy and assumes no responsibility or liability arising out of its use by others. Further, the information and suggestions are not intended to substitute for any testing you may need to conduct to determine for yourself the suitability of a particular material for a particular purpose. DuPont makes no guarantee of results and assumes no obligation or liability in connection with the use of the information or suggestions provided in this seminar.
3 Pushing Back the Barriers to Metal Replacement Presented by: Bob Tabasko Superstructural Market Development Leader Gary Kozielski Technical Consultant Superstructural Products
4 Agenda 1 2 3 4 5 6 Introduction to Superstructural Product Line Portfolio Key Properties Major Benefits Versus Metals & Other High Performance Polymers Applications Summary
5 The Introduction to Superstructural Family of resins with exceptional structural properties Potential to provide: ultra high, consistent stiffness and strength capability outstanding impact performance excellent creep resistance structural performance at elevated temperatures Based upon: Zytel HTN high performance polyamide technology (greater than 35% glass reinforced) Long glass fiber reinforced Zytel HTN and PA66 resins Rynite glass-reinforced polyester
6 The Introduction to Superstructural Less than 4% of metal applications have been converted to engineering plastics. Superstructural grades open up a host of new metal replacement opportunities!
7 Agenda 1 2 3 4 5 6 Introduction to Superstructural Product Line Portfolio Key Properties Major Benefits Versus Metals & Other High Performance Polymers Applications Summary
8 Pushing Back the Barriers to Metal Replacement Steel Al Zn Tensile Strength Reinforced Standard EP Resins Unreinforced Tensile Modulus
9 Pushing Back the Barriers to Metal Replacement Steel Al Zn Tensile Strength Superstructural Reinforced Standard EP Resins Future Unreinforced Tensile Modulus
10 Superstructural Key Grades Reinforcement Type Filler Level Zytel HTN51 Zytel HTN52 Zytel HTN53 Zytel HTN54 Zytel PA66 Rynite PET Standard Fiber Length 45 51G45HSL 52G45HSL Rynite 545 50 53G50HSLR 54G50HSLR Rynite 555 (55% glass) 60 70G60HSL Long Length 40 75LG40HSL 50 51LG50HSL 75LG50HSL 60 75LG60HSL
11 Key Features of the Zytel HTN Product Families Superstructural Ultra Stiff High Strength Excellent Creep Resistance HTN51 Series HTN52 Series HTN53 Series HTN54 Series Outstanding retention of properties with moisture Improved dimensional stability Retains high level of stiffness up to 140 C PPA resin Highest melting point and deflection temperature Moldable in water heated tools PPA resin Highest stiffness/strength at ambient temperatures Good toughness Outstanding surface finish Water heated tools Good toughness High burst pressure and knit line strength Retention of properties with moisture Retains high level of stiffness up to 110 C Water heated tools PPA resin
12 Agenda 1 2 3 4 5 6 Introduction to Superstructural Product Line Portfolio Key Properties Major Benefits Versus Metals & Other High Performance Polymers Applications Summary
13 What is Zytel HTN Zytel HTN high performance polyamides are partially aromatic nylons. Most, but not all, Zytel HTN resins fall within the narrower family of polymers known as PPA (Polyphthalamide), within which they offer perhaps the best combination of highest performance and ease of processing. Di-amine O Aromatic Di-acid O [ - NH-(CH 2 ) 6 - NH - C- -C- ] n
14 What is Zytel HTN Due to its Aromatic Ingredient, Parts Made With Zytel HTN Have Excellent Chemical Resistance, and High Temperature Performance Polyamide Aromatic Di-Acids Aliphatic Aromatic (Partially) Aromatic (Partially) PPA Aromatic (Fully) Aramid 0% Less Than 55% 55% or More 100% Examples: Zytel PA66 Zytel PA6 Zytel PA612 HTN53 PAMXD6 PA66 + PA6I/6T HTN51 HTN52 HTN54 Other PPAs KEVLAR NOMEX
15 Superstructural: LFRTs Long Fiber Reinforced Thermoplastics Fiber length in granules 12 mm Fiber length in molded parts are typically 3 4 mm versus 0.3 mm for standard glass fiber resins Component design plus processing conditions govern average fiber length and therefore part performance Knit line strength of LFRTs may also be an issue for certain designs Specific guidelines are available from DuPont for both of these points
16 Ultra High Strength and Stiffness 260 240 Glass fiber reinforced engineering polymers Polyamides conditioned to 50% RH 220 Stress at Break (MPa) ISO 527 200 180 160 140 120 PA46 50% GF PA66 43% GF PP 50% Long glass PPS 40% GF PBT 50% GF PPS 50% Long Glass 100 8 10 12 14 16 18 20 Tensile Modulus DAM (GPa) ISO 527
17 Ultra High Strength and Stiffness 260 240 Glass fiber reinforced engineering polymers DuPont EP Superstructural standard glass fiber reinforced products Zytel HTN51G45HSL Polyamides conditioned to 50% RH 220 Zytel HTN53G50HSLR Stress at Break (MPa) ISO 527 200 180 160 140 120 PA46 50% GF Zytel HTN52G45HSL Zytel HTN54G50HSLR Zytel 70G60HSL Rynite 545 Rynite 555 PA66 43% GF PPS 40% GF PPS 50% Long Glass PBT 50% GF PP 50% Long glass 100 8 10 12 14 16 18 20 Tensile Modulus DAM (GPa) ISO 527
18 Ultra High Strength and Stiffness 260 Glass fiber reinforced engineering polymers Polyamides conditioned to 50% RH 240 DuPont EP Superstructural standard glass fiber reinforced products DuPont EP Superstructural long glass fiber reinforced products Zytel HTN51G45HSL Zytel HTN51LG50HSL 220 Zytel 75LG50HSL Zytel HTN53G50HSLR Stress at Break (MPa) ISO 527 200 180 160 140 120 PA46 50% GF Zytel Zytel HTN52G45HSL 75LG60HSL Zytel 75LG40HSL Zytel HTN54G50HSLR Zytel 70G60HSL Rynite 545 Rynite 555 PA66 43% GF PPS 40% GF PPS 50% Long Glass PBT 50% GF PP 50% Long glass 100 8 10 12 14 16 18 20 Tensile Modulus DAM (GPa) ISO 527
19 Long Glass High Notched Impact Strength and Modulus 70 Glass fiber reinforced engineering polymers Polyamides conditioned to 50% RH Notched Charpy Impact Strength (kj/m 2 ) ISO 179 60 50 40 30 20 10 0 DuPont EP Superstructural standard glass fiber reinforced products PA46 50% GF PA66 43% GF PP 50% Long glass Zytel 70G60HSL PPS 40%GF Zytel HTN51G45HSL Zytel HTN53G50HSLR Zytel HTN54G50HSLR Rynite 545 Rynite 555 6 8 10 12 14 16 18 20 Tensile Modulus (GPa) ISO 527
20 Long Glass High Notched Impact Strength and Modulus Notched Charpy Impact Strength (kj/m 2 ) ISO 179 70 Glass fiber reinforced engineering polymers Polyamides conditioned to 50% RH DuPont EP Superstructural standard glass fiber reinforced products Zytel 75LG60HSL 60 DuPont EP Superstructural long glass fiber reinforced products Zytel 75LG50HSL 50 Zytel HTN51LG50HSL Zytel 40 75LG40HSL 30 PA46 50% GF PP 50% Long glass 20 PA66 43% GF Zytel HTN53G50HSLR Zytel 70G60HSL Zytel HTN54G50HSLR PPS 40%GF 10 Rynite 545 Rynite 555 Zytel HTN 51G45HSL 0 6 8 10 12 14 16 18 20 Tensile Modulus (GPa) ISO 527
21 Long Glass Resins Increase Multiaxial Impact Performance Zytel Long Glass resins not only offer higher drop weight impact and notched impact resistance, but the nature of the break is more contained 25 Energy to Max Load Total Energy 20 15 Joules 10 5 0 DAM ISO 663 3 mm Disc PA66 50% GR BK Zytel 75LG50L NC010 PA66 50% GR BK Zytel 75LG50L NC010
22 Benefits Through Mechanical Properties Zytel HTN Superstructural grades provide an excellent balance of strength, stiffness and impact performance compared to other glass fiber reinforced polyamides. Very low moisture effects give a major advantage Stress at Break (MPa) Tensile Modulus (GPa) 300 20 250 18 16 200 14 12 150 10 100 8 6 50 4 2 0 HTN51G45HSL PA66 43%GR HTN51LG50HSL PA46 50% GR 0 HTN51G45HSL PA66 43%GR HTN51LG50HSL PA46 50% GR DAM 50% RH DAM 50% RH ISO 527
23 Extending Temperature Extremes Long glass fiber increases the deflection temperature, allowing higher loads as temperatures heat up. 285 280 Standard Glass Long Glass DTUL, ºC ISO 75 275 270 265 260 255 250 245 240 235 PA66 50% GR Zytel 75LG50HSL HTN51G45HSL HTN51LG50HSL
24 Agenda 1 2 3 4 5 6 Introduction to Superstructural Product Line Portfolio Key Properties Major Benefits Versus Metals & Other High Performance Polymers Applications Summary
25 Superstructural: Key Benefits The Superstructural family offers a superb combination of stiffness, strength and impact resistance coupled with specific grades that are able to deliver a high temperature capability. They Can Provide The opportunity to enjoy the benefits of replacing metals in high performance components that were previously unable to be made in standard engineering polymers The possibility of producing plastic components with superior performance or alternatively with thinner section thereby reducing total cost and weight of parts We will look at these areas more closely
26 Pushing Back the Barriers to Metal Replacement DuPont Superstructural grades offer many major benefits versus metals. Let s remember the key advantages...
27 Major Weight Savings Opportunities Lighter weight provides savings in many different ways: Easier handling of parts 10 9 COPPER Reduced shipping costs 8 BRASS Automotive fuel efficiency Increasing weight per component Density (g/cc) 7 6 5 4 3 2 1 STEEL CAST IRON DIECAST ZINC and ZA ALLOYS ALUMINUM ALLOYS MAGNESIUM ALLOYS SUPERSTRUCTURAL POLYMERS 0
28 Benefits Through Light Weight Strength Superstructural Polymers Magnesium Alloy versus Aluminum = >40% weight savings with comparable strength! 133 up to 163 Aluminum Alloy 95 Mild Steel 52 Zinc 34 0 50 100 150 200 Specific Tensile Strength (MPa/s.g.)
29 Time and Cost Saving Through Reduced Number of Processing Steps 6 steps 6 Steps 6 Steps Diecasting Sheet metal construction Granules Injection Molding Finished part Metal Ingots Finished Part Finished part Sheet metal Painting Finishing Meltdown - cold chamber Molding Injection molding Only 3 Steps Painting Assembly Drilling Cutting Bending Stamping
30 Cost Savings Through Much Longer Average Tool Life Number of Shots (k) 1,200 1,000 800 600 Beware: when replacement costs of diecast tools are amortized into your part cost, the expense can really add up! 1000 k 400 450 k 200 150 k 300 k Aluminum Magnesium Zinc DuPont Superstructural Engineering Polymers
31 Other Major Benefits versus Metals Opportunity for cost saving and functional benefits through part integration Potential for highly innovative new designs Higher corrosion resistance Better surface finish with integral colors
32 Other Major Benefits versus Other High Performance Polymers DuPont Superstructural grades offer key benefits over some other polymers that you may consider...
33 Zytel HTN53G50HSLR versus PAMXD6 HTN53 Series Advantages Customer Benefits Versus PAMXD6 (Polyarylamide) Significantly better impact and elongation to break values Lower density (2.5% with 50% glass level) Mold tool temperature of 90 C compared to 140 C plus Less flash Components with much better toughness and overall balance of properties Opportunity for reduced volume cost Reduced processing costs Faster set up (crystallization rate) Reduced cycle time leads to higher production rates
34 Zytel HTN54 series versus other PPA Resins HTN54 Series Advantages Customer Benefits Versus Other PPA Resins Higher overall toughness (impact and elongation to break) Water heated mold capability Components with greater durability in high abuse situations Easier molding and potential for reduced cost
35 Zytel LFRTs versus Long Fiber Reinforced PP Zytel LFTR Advantages Customer Benefits Versus Long Fiber Reinforced PP Significantly higher strength (>70% increase) Opportunity to have higher performance parts or thinner section components with same performance Much higher notched impact strength (>65%increase) Components with greater durability in high abuse situations or new markets Higher stiffness particularly at elevated temperatures Parts with extended performance capability or opportunity to open up new markets Vastly improved thermal properties (DTUL at 1.8 MPa for 75LG50HSL is 260 C versus 160 C for Long Fiber PP) Ability to develop components for more demanding environments. Greater reliability of part performance
36 Agenda 1 2 3 4 5 6 Introduction to Superstructural Product Line Portfolio Key Properties Major Benefits Versus Metals & Other High Performance Polymers Applications Summary
37 Applications The benefits of DuPont Superstructural products in action...
38 Tractor Hinge Zytel HTN53 High rigidity, impact resistance and tensile strength Lower cost versus aluminum
39 Brake Booster Zytel HTN51 High strength and low warp Lighter weight due to reduction in wall thickness (60% lighter than thermoset)
40 Spline for Auto Arm Rest Retractor Mechanism Zytel HTN53 The spline can be subject to high loads and abuse situations Previously made from machined diecast metal heavy and costly Zytel HTN53 series offers high modulus, strength and very good impact properties Lighter weight and lower cost than metals, and the parts require no finishing
41 Structural Parts for Mobile Telephones Zytel HTN53 The main frame of a mobile phone is required to hold the sophisticated electronics firmly in place, protect them if dropped, be dimensionally stable and resist exposure to household chemicals Zytel HTN53 offers high stiffness, very good impact resistance, and outstanding surface finish. Zytel HTN53 can be molded to close tolerances using water heated molds
42 Windowlift Motor Gear Housing Zytel HTN51 Previously cast aluminum Weighs 30% less than cast aluminum housing Higher efficiency Excellent retention of stiffness and strength at elevated temperatures, chemical resistance, low warpage and low shrinkage
43 Boat Propeller Rynite 555 The stiffness and strength of Rynite 555 is a key factor in limiting blade deflection and preventing deformation during fast starts and high-speed running. Higher performance Cost advantage No corrosion Engine protection Easy mounting
44 Agenda 1 2 3 4 5 6 Introduction to Superstructural Product Line Portfolio Key Properties Major Benefits Versus Other Plastics Applications Summary
45 Summary Outstanding Strength Rigidity Toughness High Temperature Capability Allowing you to enjoy the benefits of Polymers in highly demanding application areas weight saving, anti-corrosion, part cost, colors, integration New Superstructural Pushing Back the Barriers to Metal Replacement!
46 Thank you for joining us today. Please send in any questions using the Q&A function. We will be answering questions for the rest of the hour. Depending on demand, we may not be able to answer your question straight away. All questions will be logged and any questions unanswered at the end of the session will be followed-up via email. Alternatively, please contact your local DuPont representative or log on to plastics.dupont.com and click on the Contact Us button. For questions about our products and how to use them, call us at the following numbers: 800-441-0575 or International 302-999-4592 Or visit us at: plastics.dupont.com
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