3.engineering plastics

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ENGINEERING PLASTICS &ITS APPLICATIONS

DR. T. O. VARGHESETECHNICAL OFFICER

CIPET Chennai

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ENGINEERING PLASTICS

Engineering Plastics are the family of Plastics that are capable of withstanding high loading for a period of time at elevated temperature and in adverse environment conditions.

Engineering Plastics exhibit a good balance of high tensile strength, Shear Strength, toughness to use as replacement of metals in many applications.

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V ADVANTAGES OF ENGINEERING PLASTICS

Rigidity with high impact strength High temperature resistance with good dimensional

stability. Outstanding resistance to corrosion Superior wear, fatigue, creep & other load bearing

properties. Intricate and multi functional part design. Easy assembly of moulded parts Elimination of finishing operations such as self

threading, etc. Ease of property modifications by using fillers. Light weight and low cost

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V PROPERTY MODIFICATIONS

By using bulk fillers, reinforced fillers, additives and blends.

BULK FILLERS: Mica, talc, calcium carbonate, asbestos, metallic powders, graphite, molybdenum disulphide

REINFORCING FILLERS: Glass fibres, carbon fibres, aramid fibres, boron fibres and synthetic fibres.

Properties of Modified Plastics Better dimensional stability – reduction in warping shrinkage and

creep Low co-efficient of thermal expansion Re-tension of mechanical properties over a much wider temperature

range Low co-efficient of friction and therefore improvement in wear

resistant property Higher stiffness and rigidity Higher impact strength at higher & lower temperatures Improvement in flexural strength and modulus Higher heat distortion temperature Imparting electrical and thermal conductivity

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FIVE MAJOR GROUPS OF

ENGINEERING PLASTICS

Crystalline materials

Polyamides Polyesters Acetals

Amorphous materials

Polycarbonates Modified Phenylene

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V POLYAMIDES The Polyamides (nylons) were the first materials to be

recognized as engineering thermoplastics.

Polyamides are polymers characterized by the amide group (CONH) as a part of the main polymer chain.

Chemically the polyamides are divided into two types:

Based on diamines and dibasic acids

Based on amino acids or lactams.

Aliphatic polyamides such as nylons 66, 6, 10 and 11 are linear polymers and thus thermoplastic.

The Nylon 6,6 is prepared from hexamethylene diamine and

adipic acid. The polyamide 6 prepared from caprolactam.

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STRUCTURE OF POLYAMIDES

Polyamide 6 -[ HN (CH2)6 CO ]-n

Polyamide 6,6 -[ HN (CH2)6 NH-CO (CH2)4 CO]-n

Polyamide6,10 -[HN(CH2)6NH-CO (CH2)8 CO]-n



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PROPERTIES

Good combination of mechanical properties like Fatigue creep strength, stiffness, toughness and resilience

Good abrasion resistance Self lubricating characteristics Suitable for prolonged, service temperature from -

400C to 1200C Good electrical insulator, but the electrical properties

are influenced by moisture content Resistance to fuels, oils, fats, most solvents and

chemicals Low permeability to gas and vapours Non-toxic Easy processable by conventional processing

techniques like injection, extrusion, blow and rotational moulding.

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APPLICATIONS OF POLYAMIDES

Automobile Industry Radiator fan Radiator grill Instrument housings Speedometer gears Fuel, oil filter housing Electrical junction box Head/Tail lamp housing Front fork bush Steering column bush

Textile Industry Drafting spacer Tension grades Magnetic holder Drive pulley Ring tubes Gears, Bushes Bobbins Yarn separators Shutters

Electrical, Electronics Industry• Circuit breaker housing Power capacitor Housing • PCB frame Cable sheathing • Switch/Switch parts Terminal block • Battery casing Potentiometer spindle • Insulator housings Ventilator fan

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Engineering Industry

Miscellaneous

Gears/Bushes Door handles

Channels and profiles Latched/Hinges

Rollers Safety helmets

Fasteners Shoe soles/studs

Ropeway tyres Moulded zips

Coupling components Impellers/fans Bearings Water meter housings Nuts and washers

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BLENDS OF POLYAMIDESPA/ABS BLENDS Impact and abrasion resistance Chemical and heat resistance Low moisture absorption Good processability and surface finish

APPLICATIONAutomotive, chemical, electrical, consumer and sport industries.

PA/ELASTOMER (EPDM/EPR) BLENDS Low temperature impact strength Good processability The moulded articles can suppress vibration even at subzero temperature

APPLICATIONAutomotive, home appliances, sport, business equipments and consumer products.

PA/PP BLENDS Shows good processability Reduced water absorption Low density (ie. Low cost per volume Improvement in paintability

APPLICATIONSAutomotive, building, furniture & industrial

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POLYACETAL

Acetalpolymers are properly called polyoxymethylene (POM).

These resins are linear unbranched molecular chains derived from the monomer formaldehyde. The structure of homopolymer and copolymer are as follows:

---- CH2 - O - CH2 - O - CH2 - O - CH2 ------Polyacetal homopolymer

---- CH2 - O - CH2 - CH2 - O - CH2 ------ Polyacetal Copolymer

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PROPERTIES

Excellent combination of toughness, rigidity, fatigue, strength and yield strength (spring like qualities)

Good wear resistance Low co-efficient of friction Service Temperature Range 90 - 1200 .C Good dimensional stability over wide

temperature -400.C to 650 .C Good moisture and chemical resistance Good electrical insulation Easy processable with conventional technique Excellent dimensional accuracy and post

moulding stability

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V APPLICATIONS OF POLYACETALS

Gears Bearing boxes and bushes Switch relays, terminal blocks and coil formers Blower fans, ventilation fans and pump parts Parts for office machines, house hold appliances and

bathroom fittings Hinges Springs, snap fittings, screw Curtain rail runners Aerosol nozzles Nuclear engineering applications Plumbing fittings and components for pneumatic systems Automobile components such as radiator heater tapes,

water filter bodies, fuel contact applications In irrigation system used in the areas of compression

fittings, jets and sprayers Clock and watch parts

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POLYACETAL BLENDS

POM/TPU BLENDS

High impact strength High fatigue, flexural and tensile strength Low water absorbency Good resistance to oils, greases and many

chemicals Most blends contain 10-30 wt. % of TPU Blends have co-continuous morphology for

good performance

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POLYCARBONATE

Polycarbonate is a linear polyester of carbonic acid in Which dihydric phenols are lined through carbonate groups. The commercial grades of polycarbonate is manufactured from bisphenol-A and phosgene. The structure of polycarbonate is:

O CH3

ll l

-[ C - O - - C - - O ]-n

l

CH3

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PROPERTIES

High impact strength even at sub zero temp. Remains flexible down to -150 ºC Good creep resistance in dry conditions up to 115ºC Non-flammable, self extinguishing High heat deflection temperature Good dimensional stability Resistance to weak acids, hydrocarbons and oils Good electrical properties, stable over wide range of

temperature, frequency and humidity Can be injection moulded, compression, transfer and

blow moulded, extruded and easily machinable

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V APPLICATIONS OF POLYCARBONATE

TRAFFIC AND AUTOMOTIVE

• Housing and colored lenses for traffic signals• Reflectors • Ventilation and radiator Grills• Bumpers Wind shields for two• Wheelers• Headlight • Lenses • Tail lamps • Fuse box covers • Wind screen • Wiper bracket

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ELECTRICAL / ELECTRONICS ENGINEERING

• Housing for computers • Telephone housings for

mining operations • Plug and socket

Terminal blocks

• Coil former and housing

• Compact discs

• Battery covers

MEDICAL INDUSTRIES

Dispenser for inhalers Surgical lights Sterilizable lab wares

Tissue culture Dishes Blood bottles Housing for blood

cleaning filters

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HOUSEHOLD AND DOMESTIC WARES

• Baby feeding bottles • Table wares • Water containers

• Coffee filter • Mixers and blenders • Vacuum cleaner

Housings

Safety helmets Safety glazing

Goggles Green house

MISCELLANEOUS

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POLYCARBONATE BLENDS

PC/ABS BLENDS Moulding characteristics High impact strength at low temperature

PC/ASA BLENDS Rigidity and dimensional stability Outstanding resistance to high temperature ageing Good resistance to UV radiation

PC/SMA BLENDS Superior toughness Heat resistance Outstanding processability

APPLICATIONS Automotive, medical and electronic

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V THERMOPLASTIC POLYESTERS (PET/PBT)

Polyethylene Terephthalate (PET)

O O H H

ll ll l l

-[ C - - C - O - C - C - O ]-n

l l

H HPolyethylene terephthalate produced by the condensation reaction of ethylene glycol with either terephthalic acid (TPA) or dimethyl terephthalate (DMT).

The production of PET resin is two step process. Dimethyl terephthalate is heated with ethylene glycol to form a

mixture of dihydroxyethyl terephthalate and higher oligomers. Step two is further heating to 270oC under vacuum, with the catalytic

conversion of dihydroxyethyl terephthalate to PET.

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V POLYBUTYLENE TEREPHTHALATE (PBT)

O O H H H H ll ll l l l l

-[ C - - C - O - C - C - C - C - O ]-n l l l l

H H H H

Polybutylene terephthalate (PBT) is also called poly tetramethylene terephthalate (PTMT) is a semi-crystalline polyester resin.

PBT is produced by the catalytic polycondensation of 1, 4-butanediol and dimethyl terepathalate.

Subsequent post-condensation raises transesterified product to the desired molecular weight.

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PROPERTIES

• Good electrical property • Superior strength and stiffness • Excellent dimensional stability • Water repellants • Outstanding chemical resistance • Sterlisable by ethylene oxide and gamma

rays • Good abrasion resistance• Low co-efficient of friction

• Excellent flame retardance

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APPLICATIONS OF PET

Synthetic fibre - Screen and sewing thread Biaxially oriented film - Magnetic tape - X-ray and photographic film - Electrical insulation tapes - Food packaging Blow moulded containers Automotive components Electrical components Power tool housings Appliance bases Medical device packaging

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V APPLICATIONS OF PBT

Electrical - Coil bobbinsConnectorsTV turnersHigh voltage componentsRelays

Automotive - Fuel injection controls

Ignition coil capsSpeedometer framesGearsLamp sockets

Domestic - Electric coffee makersAppliances Toasters

SwitchesCoil cylindersWashing machines

Components

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V BLENDS OF THERMOPLASTIC POLYESTRS

PET/PC BLENDS Improved process stability Excellent impact and chemical resistance Reduce co-efficient of friction with improved dimensional stability

APPLICATIONSAutomotive, recreation equipment, components for hydraulic systems

PET/Elastomer BLENDS Good processability, rigidity Excellent weatherability Improved impact strengthAPPLICATIONElectrical/Electronics, Automotive and hardware applications

PBT/ABS BLENDS Show excellent processability with high gloss Stiffness at high temperature Low shrinkage Resistance to gasoline and motor oilsAPPLICATIONSElectrical/Electronics, Automotive, office and house hold equipments

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POLYPHENYLENE OXIDE - PPOThe chemical formulation is based on the oxidative coupling of substituted phenols and the elimination of a molecule of water. The full chemical name of PPO is poly [1, 4 – (2, 6-dimethyl phenyl) ether].

CH3

-[ - - O - ]-n

CH3

PPO is used in blends with other Polymers. The neat Polymer is not suitable for injection moulding because of its high melt viscosity.

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PROPERTIES

High Heat Resistance Excellent Impact Strength Exceptional dielectric and dissipation characteristics Flame Retardancy Exceptional low moisture absorption

Blends of Polyphenylene Oxide

PPO/PS blends, PPO/PA blends Polyphenylene Oxide is completely miscible with

Polystyrene in all proportions.

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APPLICATIONS

Automotive

Fenders, dash- boards,

Head lamp systems,

Instrument and Control Panels,

Mud-guards,

Wheel Covers &

Fuse Blocks etc.

CommunicationsComputer Housings,Television Cabinets,Telephone and Fiber Optic Connectors,Video display terminals,Control Panels,Printer Bases etc.

Appliances

Air conditioner grills and

Components

Pump housings for dish

washers & Cloth-Washers,

Handles etc..

Electrical

Plug and Socket Connectors,

Electrical Wall Plates,

Outlet boxes,

Connectors,

Switches etc..

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ACRYLONITRILE BUTADIENE STYRENE (ABS)

PROPERTIES Good combination of mechanical, thermal and chemical

properties Low cost of all engineering thermoplastics High impact strength Low continuous use temperature High thermal expansion Limited weather resistance Poor solvent resistance Low water absorption Easy processable by injection, extrusion and vacuum forming Electroplatable

- CH2 – CH – CH2 – CH = CH – CH2 - CH2- CH -

CN x y z0

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APPLICATIONS OF ABS

Telephone casings Housing for domestic appliances eg. Vaccum

cleaners, TV cabinets, etc. Luggage cases Safety helmets Car fascia and instrument panels Toys Furniture Food mixture housings Automobile radiator grills Refrigerator door and tank liners Automotive front and assembly

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V BLENDS OF ABS

ABS/PC BLENDS High impact strength and hardness Improved HDT compared to ABS Dimensional stability Electrical properties independent of moisture and temperature

APPLICATIONSElectrical and Electronics appliances, Automotive parts

ABS/PVC BLENDSFlame resistance

APPLICATIONSElectrical appliance housing, Automotive instrument panels

ABS/TPU BLENDS Very high impact strength TPU contributes lubricity, wear resistance, toughness, low

temperature impact strength ABS provides increased stiffness and improved processability

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V POLYTETRA FLUOROETHYLENE (PTFE)

PROPERTIES Inert to all chemicals Excellent weatherability and not attacked by bio-organisms Anti-stick and low friction Stable at high temperature (upto 250 Deg.C) Tough at low temperature (down to –160 Dec.C.) Self extinguishing Stable electrical properties and non-tracking Difficult to process by conventional methods Processed by sintering technique Easy machinable

- C – C -

F F

F Fn

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APPLICATIONS

High and low temperature electrical and electronic insulationBearingsWear resistant, low friction surfacesChemical process equipmentsValvesPump impellersGasketsNon-stick cockwares

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THERMOPLASTIC POLYURETHANES (TPU)

PROPERTIES High wear resistant Flexibility over a wide range of temperatures Good resistance to oils, greases and many

solvents Good weatherability Absence of plasticisers Excellent resistant to high energy radiation Excellent resistant to decay

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APPLICATIONS OF TPUAutomotive Bearings and bushes for oscillating parts, strikers and seals for door

locks, vibration-damping components, diaphragms, sleeves, control

cable guides, covers for flexible hydraulic hoses, shock absorber

components.

Engineering Low-noise gearwheels, seals, sleeves, wipers, clutch components,

toothed belts, hoses, rolls, castor covers, skating rollers, pickers.

Tool Hammer heads, sand disc back-up pads, wipers.

Footwear Sports shoe soles, studs and bars, heel tips, ski boots.

Electrical Vibration-damping components, covers for geophysical and and sea survey cables, abrasion resistance cable sheathings.

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SPECIALITY PLASTICS

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V POLYPHENYLENE SULPHIDE(PPS)

PROPERTIES Good fatigue, creep and dimensional stability Continuous use at 240 Deg.C. Non-burning Very good chemical resistance even upto 190-200 Deg.C Low water absorption Good radiation resistance

APPLICATIONS

Electrical & Electronics

Connectors, sockets, coil formers, floppy disc heads, bush holders, insulating plates

Automotive

Valves, carburator parts, lamp sockets Industrial Pump

components, metering equipment, medical/dental equipments

O - - S -

n

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POLYSULPHONE (PSU)

PROPERTIES Good dimensional stability Good thermal stability Excellent creep resistance Self extinguishing Resistance to mineral acids, alkalies, salt solution, detergents and oils. Good oxidative stability at elevated temperature Can be used continuously in steam at temperature upto 150 ºC Good electrical properties Transparent in nature

O -C- O -O- -SO2O O -O--

nCH3

CH3

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APPLICATIONSAppliances

Dish washer parts, Microwave oven parts, Beverage dispensers, coffee pot / makers, steam table pans and bowls.

Electrical/Electronics

Connectors, fuse bodies, switch housings, coil bobbins, TV components and computer parts

Medical

Chemotherapy devices, electro surgical and cryogenic surgical tools, membranes for renal dialysis, inhalers, pharmaceutical filtering devices, surgical tray, sterlizing equipments parts

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POLYETHER SULPHONE (PES)

PROPERTIES Amorphous in nature Transparent with 60-80 % light transmittance Good thermal stability Excellent creep resistance and load bearing properties upto

100 ºC Good dimensional stability upto 200 ºC Good electrical properties Good flame resistance Good resistance to gamma radiation Low mould shrinkage Can be electroplatable.

O- - S - O O- -n

O

O

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APPLICATIONS

AutomotiveIndicator lights, car heater fans, aircraft components, reflectors and industrial control relays

ElectricalTransformer coil formers, multi pin connectors and relays, terminal blocks, chip trays and carriers

AppliancesMicrowave oven bowl holders, hot combs, hair dryer components, projector lamp grills

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V POLYETHER ETHERKETONE (PEEK)

PROPERTIES Inert polymer, having very high heat stability Very high melting temperature (335 ºC) Excellent chemical resistance Excellent tribiological properties Very strong and rigid Excellent fatigue resistance Exhibits good load bearing properties Excellent creep resistance Excellent flammability rating and low emission of smoke and toxic gases

during combustion Very good electrical properties over a wide range of temperature

O- -O- O C- -n

O - O -

O

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APPLICATIONS

Aerospace Glass/carbon fibre reinforced composites for

aerospace components, missile connectors and radors.

Automotive Cages, gear support bearings, clutch seals,

transmission parts, rollers, gears, guides

Electrical Connectors and insulation components

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V POLYARYLATES

PROPERTIES Excellent dimensional stability Good warp resistance Rigid strong and tough in nature Good resistance to chemicals Good flame retardance High heat resistance Transparent and excellent UV resistance

O- -C - O - - C-

n

O - O -O

CH3

CH3

O

- C

O

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APPLICATIONS

AutomotiveLenses for automobile lamps, exterior glazing, reflectors, lamp housings, door handles, wind shield wipers and mirror housings

ElectricalSolar energy collector glazing, connectors relays, fuse covers, switches, coil formers/bobbins

IndustrialAutomobile seals, rotors for pumps, fire shields, mixing light covers, fire helmets, safety equipment housings

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POLYAMIDE – IMIDE (PAI)

PROPERTIES Good resistance to chemicals Excellent resistance to radiation Very high mechanical properties High temperature stability Continuous use temperature is 200 ºC High stiffness Inherently flame resistance having LOI 43%

O

-C-C

CN- -CH2-O O -NH-

O

O

O

n

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APPLICATIONSAerospace Jet engine components, compressor & Generator

parts, fasteners

Adaptors and electronic connectors.

Automotive Transmission, Thrust washers & piston rings,

ball bearings, wear surface Bushings, seals, flow control components, racing

engine connecting Rods, thrust washers, gears.

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V POLYETHER – IMIDE (PEI)

PROPERTIES Very high mechanical properties Resistance to most chemicals Excellent resistance to UV radiations Can be stabilised by ethylene oxide and gamma radiation Excellent flame resistance Exhibits the highest LOI 47% Very good thermal stability and warp resistance at elevated temperature

O

-NC

-C- NO O

O

-O-n

C

OCH3

CH3

-O-

O C

C

O

O

O

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APPLICATIONS

IndustrialCorrosion resistant fluid and gas handling parts, strong mechanical couplers and threaded fasteners, bearing sleeves.

MedicalNerve simulators, surgical lamp housings, manifold valves for ventilators, endodontic cases

Electrical/Electronics Precision fibre optic components PCB and IC chip carriers, bobbins, protective clothing for fire fighters, insulating tapes and wire insulators.

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V LIQUID CRYSTAL POLYMERS (LCP)

PROPERTIESPossess superior elevated temperature performanceHigh mechanical strength upto 300 Deg.CVery good flame retardantBetter electrical propertiesGood chemical resistance

APPLICATIONSAppliances: Cook wears used in microwave ovens. Microwave oven parts like, floor, ceiling parts, stirrer assembly and turn table assemble parts.

Machinery/Equipment: Circuit boards, Semi-conductor handling devices, parts for electric motors.

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S.No. PolymerNature of fiber

Wt%

Tensile strength

(psi)

Elongation (%)

Flexural modulus

(psi x 105)

Izod Impact

Strength (ft.lb.in1)

1.Polyamide 66

NoneGFCF

04040

118003100040000

602 – 33 – 4

4.116.034.0

0.92.91.6

2. Polysulphone

NoneGFCF

03030

102001800019000

50 –1003

2 - 3

3.912.025.5

1.31.81.1

3. PolypropyleneNoneGF

030

50009800

200 – 7002 – 3

2.08.0

0.51.6

4. PolycarbonateNoneGF

0 30

950016000

904 – 6

3.412.0

2.73.7

5. Polyphenylene oxid

NoneGF

030

950018500

603 – 4

3.611.5

1.21.7

MECHANICAL PROPERTIES OF UNFILLED

AND FILLED PLASTICS

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V HDT FOR UNFILLED AND FILLED PLASTICS

S.No PolymerHeat Distortion Temperature ºC

(at 264 psi)

Unfilled 30% GF filled

1. Polypropylene 55 – 60 146

2. Polybutylene terephthalate 55 200 – 212

3. Polyethylene terephthalate 68 221

4. Polycarbonate 140 149

5. Polysulphone 174 185

6. Polyphenylene oxide 130 155

7. Polyamide 6 70 215

8. Polyamide 6,6 104 255

9. Polyphenylene sulphide 135 260

10. Polyether ether ketone 160 315

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S.No. Polymer

Co-efficient of Linear Thermal Expansion

(in-1 ºF-1 x 10-5)

Unfilled30% GF

filled

1. Polypropylene 3.8 2.0

2. Polybutylene terephthalate

4.6 1.2 – 5.4

3. Polycarbonate 3.73 1.25

4. Polysulphone 3.1 1.4

5. Polyamide 6 4.6 1.7

CO-EFFICIENT OF LINEAR THERMAL EXPANISON FOR

UNFILLED AND FILLED PLASTICS

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S.No. PolymerNature of

FibreWt.%

Dielectric strength (Vmil-1)

Arc Resistance

(S)

1. Polyphenylene sulphide

NoneGF

030

400 – 500 550 – 600

70 – 80 100 – 120

2. Polycarbonate NoneGF

030

390 – 410 450 – 480

110 – 120110 – 120

3. Polyamide 6 NoneGF

030

360 – 370400 – 480

130 – 140125 – 135

DIELECTRIC STRENGTH AND ARC RESISTANCE FOR UNFILLED AND FILLED PLASTICS

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S.No. PolymerMould Shrinkage (mm/mm)

Unfilled 30% GF filled

1. Polypropylene 0.01 – 0.025 0.002 – 0.008

2. Polybutylene terephthalate

0.017 – 0.023 0.002 – 0.006

3. Polycarbonate 0.007 0.0025

4. Polysulphone 0.007 – 0.008 0.002 – 0.003

5. Polyphenylene oxide 0.005 – 0.007 0.002 – 0.004

6. Polyamide 6 0.016 0.0045

MOULD SHRINKAGE

FOR UNFILLED AND FILLED PLASTICS

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3.engineering plastics

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