Wear Resistant Thermoplastics April2011

STRUCTURAL ELASTOMERS WEAR COLOR CONDUCTIVE FLAME RETARDANT FILM/SHEET
Wear Resistant Thermoplastic Compounds

Dr. Joel Bell Product Development Engineer RTP Company
Agenda
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
RTP Company Introduction Definitions & Test Methods Morphology Additive Technologies Application examples
GLOBALIZATION STRATEGY
Asia
Scalability: Develop your solution on a small scale and produce your solution at larger quantities Plant-to-plant consistency Identical machinery, processing, QA testing
United States
France
ISO 9001:2008 Registered Facilities Worldwide technical support Local customer service: real people, real time
PRODUCT FAMILIES
STRUCTURAL
WEAR RESISTANT
CONDUCTIVE
ELASTOMERS
FLAME RETARDANT
COLOR
FILM/SHEET
Compounds formulated to meet your needs
Definitions
Tribology Definition
The Science of the mechanisms of friction, lubrication, and wear of interacting surfaces that are in relative motion.
Mechanisms of Wear
Adhesive Wear
The primary mechanism for thermoplastic wear. Characterized by transfer of material from one part to the other caused by frictional heat.
Mechanisms of Wear
Abrasive wear Caused by a hard material scraping or abrading away at a softer material. Characterized by grooves cut or gouged into the surface.
Three Body
Coefficient of Friction ()
Friction is the natural resistance to the sliding motion of one surface over another Static Coefficient of Friction (s) = Fx/Fy
Fx = Force to initiate motion Fy = Normal force holding surfaces together
Dynamic Coefficient of Friction (k) = Fx/Fy

Fx = Force to sustain motion Fy = Normal force holding surfaces together
Slip/Stick
Thermoplastics Are Unique

Static friction is typically less than dynamic friction
Can Lead To Slip/Stick
Too large of difference leads to squeaking
ASTM D1894 Friction Test

Sled Test
Coefficient of Friction Testing Does not determine wear resistance
Can Show Slip/Stick
ASTM D3702 Wear Test

Standard conditions
Steel Thrust Washer 40 psi: 50 ft/min (2000 PV) Ambient Temp 100 hour test
Counter-surface (thrust washer) material, pressure, velocity and temperature are all adjustable The best use of this test is to perform comparative screening of multiple candidate materials
ASTM D3702 Wear Tester

Calculating Wear Factor (K)

Wear Factor (K)
K = W/(F x V x T)
K = Wear Factor: (in3-min/ft-lb-hr)10E-10 or (mm3/N-m)10E-8 F = Force: lb or N V = velocity: ft/min or m/sec T = Elapsed Time: hr or sec W = volume wear: in3 or mm3
Wear factor per unit pressure can be calculated by multiplying the standard wear factor value by 0.35in2. KP = Wear Factor: (in5min/ft-lb-hr)10E-10 (Some companies report wear factors this way)
Additive Technologies
Morphology Characteristics
Amorphous Semi-Crystalline
Low Shrinkage Low Warpage Tight Tolerances Transparency Mold Flow Ease Chemical Resistance Response to Reinforcement Wear Resistance X X X X X X X X
Traditional Technologies
1. PTFE Polytetrafluoroethylene (10-20%)

Workhorse additive solid white powder Homogeneously distributed throughout the polymer matrix Forms a lubricious layer at polymer surface Requires a Break-in period Compatible with nearly all thermoplastic resins
Drawbacks
Fluorine content Die plate-out Relatively high loadings
PTFE Mechanism
Application
Automotive Seat Adjustment Lever Needs good strength, stiffness and wear resistance. (Structural, wear, precolor) Glass fiber reinforced PTFE lubricated and precolored PPA.
2. Silicone Polydimethylsiloxane (1-3%)

Boundary lubricant which migrates to the surface over time Migration rate is viscosity dependent Excellent friction reducer Best in high speed/low load applications Used with PTFE to eliminate Break-in period
Drawbacks
Limited use in decorated parts
Poor adhesion of paint or print inks
Bad for electrical applications

Can foul contacts
PTFE Break-In Period with Silicone

Industrial Application
Food Handling conveyor rollers
Antimicrobial, low friction. (Antimicrobial, Wear) PTFE and silicone lubricated POM with antimicrobial additive
Wear of POM, PA 6/6 and PC

Wear Factor (K)
POM PA 6/6 PC
8000 7000 6000 5000
7500
4000 3000 2000 1000 0
1500 675 150 60 200 40 102
175
PC PA 6/6
POM
Neat Resin
2% SI
20% PTFE
Additive(s)
Values per ASTM D3702 test method vs C1018 Steel Wear Factor Units: (in3min/ft/lb/hr)E-10
3. Graphite Powder (5-15%)

Aqueous environments Excellent temperature resistance Black (Charcoal Gray) color
4. Molybdenum Disulfide MoS2 (1-5%)

Nucleating agent in nylons: creates harder surface High affinity to metal: smoother mating metal surface = lower wear
Drawbacks
Limited use Dark color limits colorability Sloughing type additives
Application
Water Meter Valve
Dimensional stability, potable water contact - NSF listed. (Structural, Wear) Graphite lubricated SAN & PS
Fiber Reinforcements
1. Glass Fiber (5-50%)

Improved bearing capabilities and wear resistance Low cost
Drawbacks
Extremely abrasive to mating surface
2. Carbon Fiber (5-50%)

Greatly improved bearing capabilities Electrically and thermally conductive Less abrasive than glass
Drawbacks
High cost Black color
Technology Combinations
1. 10/10/10 Carbon fiber/Graphite Powder/PTFE

Typical additive package for high load bearing applications. Prevalent in hi temp resin systems PPS, PEEK and PPA versions available from RTP Available from some resin producers
Application
AC Compressor Scroll Seal
High temperature, chemical and wear resistance Carbon fiber reinforced and PTFE/Graphite lubricated PEEK
3. Aramid Fiber (5-20%)

Very gentle to mating material Improves wear and friction
Drawbacks
Difficult to process Minimal physical property enhancement High cost
Fibers vs. Metal

APWA
APWA All Polymeric Wear Additive (5-15%)

Alloys with host polymer Excellent Plastic vs. Plastic performance (Great for business machines) Completely halogen free Physical properties maintained No die plate-out Specific gravity benefits (more parts per lb or kg)
Drawbacks
Limited thermal resistance Higher cost Not FDA
APWA Plastic vs. Plastic wear

Wear Factor (K): APWA vs. PTFE
POM PBT PA 6/6 PC
160 140 120 100
145 121 98 90 31 47 24 29
80 60 40 20 0
PC PBT PA 6/6
10% PTFE
APWA
POM
Additive(s)
Values per ASTM D3702 test method. PV = 1000 ftlb/in2min Wear Factor Units: (in3min/ft/lb/hr)E-10
Business Machine Apps

Thermal Printer Frame High Impact, ESD, wear resistance. (Conductive, Structural, Wear) Impact modified, conductive PC with APWA for improved wear resistance
PFPE
PFPE Perfluoropolyether Oil (< 1%)

Thermally Stable up to PEEK processing temps Differentiates RTP Company from others Physical properties maintained Minimized die plate-out (improved production efficiencies) Synergy with PTFE Specific gravity benefits Improved fatigue resistance
Drawbacks
Limited effectiveness in amorphous resins Needs PTFE kick to deliver optimum friction reduction
Wear with Various Modifiers

Wear Factor (K) against Steel

Wear Factor (K)
POM PA 6/6 PC
190 222 44 10 14 19 100 100
495
500 450 400 350 300 250 200 150 100 50 0
PC PA 6/6 POM
PTFE/SI
PTFE/PFPE (<10%)
APWA
Additive(s)
Values per ASTM D3702 test method vs. C1018 Steel
PV = 2000 ftlb/in2min Wear Factor Units: (in3min/ft/lb/hr)E-10
Agricultural Pump Chemical and Wear Resistance (Structural, Wear) PFPE lubricated PP
Questions
Thank you for your attention. Any questions?
Friction of POM, PA 6/6 and PC

Dyanamic Coefficient of Friction

0.65 0.55
0.70 0.60 0.50
POM PA 6/6 PC
0.45 0.60 0.50
0.40 0.30 0.20 0.10 0.00
0.50 0.45 0.25
0.35
PC PA 6/6 POM
Neat Resin
2% SI
20% PTFE
Additive(s)
Values per ASTM D3702 test method vs C1018 Steel
APWA Plastic vs. Steel wear

Wear Factor (K): APWA vs. PTFE

326
350 300 250
POM PBT PA 6/6 PC
341
200 150 100 50 0
100 114 41 47 10% PTFE 19 100
PC PBT PA 6/6
APWA
POM
Additive(s)
Values per ASTM D3702 test method vs. C1018 Steel. PV = 2000 ftlb/in2min Wear Factor Units: (in3min/ft/lb/hr)E-10
Fluid Handling Pump
Chemical resistance, high strength & stiffness. (Structural, Wear) Glass fiber reinforced, PTFE lubricated PP
Business Machine Application

Digital Printer Cartridge Holder ESD, high strength/stiffness, low friction/wear. (Conductive, Structural, Wear) Carbon fiber reinforced, PTFE lubricated PEI
Business Machine Application

Copier Bushings Extremely high temperature resistance (~260C), wear resistance. (High Temperature, Wear) Aramid fiber reinforced, PTFE lubricated TPI
Physical Property Comparison

POM
Unfilled PTFE (20%) 1.52 6500 300,000 1.0 Silicone (2%) 1.40 7800 350,000 1.5 Unfilled 1.14 12,000 400,000 1.0
PA 6/6
PTFE (20%) 1.26 9500 400,000 1.0 Silicone (2%) 1.13 11,000 400,000 1.0 Unfilled 1.19 8500 340,000 7.5
PC
PTFE (20%) 1.31 7000 320,000 3.5 Silicone (2%) 1.19 8500 350,000 10.5
Specific Gravity Tensile Strength (psi) Flexural Modulus (psi) Notched Impact (ft-lb/in)
1.41 8700 350,000 1.5
Testing per ASTM test methods.
Physical Property Comparison

POM
PTFE/SI PTFE /PFPE 1.41 8000 340,000 1.5 APWA 1.39 8000 300,000 1.2 PTFE/SI 1.19 10500 400,000 1.2
PA 6/6
PTFE/ PFPE 1.17 10500 400,000 1.2 1.12 10000 400,000 1.1 1.24 7500 300,000 7.5 APWA PTFE/SI
PC
PTFE/ PFPE 1.25 8000 330,000 3.5 1.16 8000 350,000 10.5 APWA
Specific Gravity Tensile Strength (psi) Flexural Modulus (psi) Notched Impact (ft-lb/in)
1.44 6500 300,000 1.2
Testing per ASTM test methods.

Wear Resistant Thermoplastics April2011

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STRUCTURAL ELASTOMERS WEAR COLOR CONDUCTIVE FLAME RETARDANT FILM/SHEET

Wear Resistant Thermoplastic Compounds

Compounds formulated to meet your needs

STRUCTURAL ELASTOMERS WEAR COLOR CONDUCTIVE FLAME RETARDANT FILM/SHEET

Dynamic Coefficient of Friction (k) = Fx/Fy

Thermoplastics Are Unique

Too large of difference leads to squeaking

ASTM D1894 Friction Test

Can Show Slip/Stick

ASTM D3702 Wear Test

ASTM D3702 Wear Tester

Calculating Wear Factor (K)

Wear Factor (K)

STRUCTURAL ELASTOMERS WEAR COLOR CONDUCTIVE FLAME RETARDANT FILM/SHEET

1. PTFE Polytetrafluoroethylene (10-20%)

2. Silicone Polydimethylsiloxane (1-3%)

Bad for electrical applications

PTFE Break-In Period with Silicone

Food Handling conveyor rollers

Wear of POM, PA 6/6 and PC

Wear Factor (K)

8000 7000 6000 5000

4000 3000 2000 1000 0

1500 675 150 60 200 40 102

3. Graphite Powder (5-15%)

4. Molybdenum Disulfide MoS2 (1-5%)

Water Meter Valve

1. Glass Fiber (5-50%)

2. Carbon Fiber (5-50%)

1. 10/10/10 Carbon fiber/Graphite Powder/PTFE

AC Compressor Scroll Seal

3. Aramid Fiber (5-20%)

Fibers vs. Metal

APWA All Polymeric Wear Additive (5-15%)

APWA Plastic vs. Plastic wear

Wear Factor (K): APWA vs. PTFE

POM PBT PA 6/6 PC

160 140 120 100

Business Machine Apps

PFPE Perfluoropolyether Oil (< 1%)

Wear with Various Modifiers

Wear Factor (K) against Steel

Thank you for your attention. Any questions?

Friction of POM, PA 6/6 and PC

Dyanamic Coefficient of Friction

0.45 0.60 0.50

0.40 0.30 0.20 0.10 0.00

0.50 0.45 0.25

APWA Plastic vs. Steel wear

Wear Factor (K): APWA vs. PTFE

POM PBT PA 6/6 PC

200 150 100 50 0

100 114 41 47 10% PTFE 19 100

Fluid Handling Pump

Business Machine Application

Business Machine Application

Physical Property Comparison

1.41 8700 350,000 1.5

Testing per ASTM test methods.

Physical Property Comparison

1.44 6500 300,000 1.2

Testing per ASTM test methods.

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