Torlon® Resins Engineering Data

Transcription

Solvay Advanced Polymers
Torlon Resins Engineering Data
®
Automotive
Drivetrain
Thrust Washers
TORLON®
poly(amide-imide)
resin drive train
thrust washers in
automotive
applications have
superior impact
strength, wear
resistance, and
chemical resistance.
Diesel Engine Thrust Washers
TORLON® poly(amide-imide) thrust washers
absorb and dissipate impact energy in truck
engines. They offer low friction and wear,
high pressure and velocity limits, excellent
mechanical properties and heat resistance.
Check Balls for 4-Wheel-Drive
Vehicle Transmissions
The durability of high-torque automatic
transmissions was improved when
Chrysler product development engineers
specified Torlon® poly(amide-imide) resin
for the check balls. The resin was selected
for multiple variations of three- and
four-speed transmissions coupled to the
Magnum Engine product line. The check
balls withstand system pressures, and
provide excellent sealing surfaces without
causing metal damage, and without
adverse reaction to transmission oil at
temperatures approaching 300°F.
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
®
TORLON High Performance Molding Polymers. . . . 7
The High Performance TORLON Polymers . . . . . . . . 8
Physical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Typical Properties – US Units . . . . . . . . . . . . . . . . . . 10
Typical Properties – SI Units . . . . . . . . . . . . . . . . . . . 11
Performance Properties. . . . . . . . . . . . . . . . . . 12
Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . 12
Tensile and Flexural Strength at Temperature
Extremes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Ultra High Temperature . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tensile Properties Per ASTM D638. . . . . . . . . . . . . . . . 13
Ultra Low Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Flexural Modulus-Stiffness at High Temperature . 13
Stress-Strain Relationship . . . . . . . . . . . . . . . . . . . . . 14
Resistance To Cyclic Stress . . . . . . . . . . . . . . . . . . . . 15
Fatigue Strength. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Impact Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fracture Toughness . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Thermal Stability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Thermogravimetric Analysis . . . . . . . . . . . . . . . . . . . 18
Effects of Prolonged Thermal Exposure . . . . . . . . . 18
Ul Thermal Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Retention of Properties After Thermal Aging . . . . . 18
Specific Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Thermal Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . 20
Metal-Like Coefficients of Linear Thermal Expansion
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Creep Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Flammability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Summary of Flammability Data . . . . . . . . . . . . . . . . . 23
Performance in Various Environments . . . . . . . . . . . 24
Chemical Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . 24
Resistance To Automotive and Aviation Fluids. . . . . . 25
Chemical Resistance Under Stress . . . . . . . . . . . . . 25
Effects of Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Absorption Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Equilibrium Absorption at Constant Humidity . . . . . . . 26
Dimensional Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Restoration of Dimensions and Properties . . . . . . . . . 27
Changes in Mechanical and Electrical Properties. . . 27
Constraints on Sudden High Temperature Exposure. 27
®
Weather-Ometer Testing . . . . . . . . . . . . . . . . . . . . . 28
Resistance to Gamma Radiation . . . . . . . . . . . . . . . . 28
Electrical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TORLON polymers for insulating . . . . . . . . . . . . . . . . 29
Conductivity and EMI Shielding . . . . . . . . . . . . . . . . 30
Service Under Conditions of Friction and Wear . . . 32
An Introduction to TORLON Wear Resistant Grades
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wear Rate Defined as PV Service Limits. . . . . . . . . 32
Unlubricated Wear Resistance . . . . . . . . . . . . . . . . . 32
Evaluation by Thrust Washer Friction and Wear
Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Effect of Mating Surface on Wear Rate. . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Lubricated Wear Resistance . . . . . . . . . . . . . . . . . . . 35
Wear Resistance and Post-Cure. . . . . . . . . . . . . . . . 35
Industry and Agency Approvals . . . . . . . . . . . . . . . . 36
Structural Design . . . . . . . . . . . . . . . . . . . . . . . 37
Material Efficiency—Specific Strength and
Modulus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Geometry and Load Considerations. . . . . . . . . . . . . . 38
Examples of Stress and Deflection Formula
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Example 1–Short-term loading . . . . . . . . . . . . . . . . . . . 38
Example 2-Steady load . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Example 3-Cyclic load . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Stress Concentration . . . . . . . . . . . . . . . . . . . . . . . . . 39
Recommended Maximum Working Stresses for
TORLON Resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
®
Designing with TORLON Resin . . . . . . . . . . . 39
Fabrication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Injection Molding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Extrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Compression Molding . . . . . . . . . . . . . . . . . . . . . . . . . 39
Post-curing TORLON Parts . . . . . . . . . . . . . . . . . . . . . 40
Guidelines for Designing TORLON Parts . . . . . . . . . 40
Wall Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wall Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Draft Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Ribs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Bosses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Undercuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Molded-in inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Secondary Operations . . . . . . . . . . . . . . . . . . . 43
Joining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Mechanical Joining Techniques. . . . . . . . . . . . . . . . 43
Snap-fit: Economical and Simple . . . . . . . . . . . . . . . . . 43
Threaded Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Self-tapping Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Molded-in Inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Threaded Mechanical Inserts . . . . . . . . . . . . . . . . . . . . 43
Molded-in Threads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Interference Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Ultrasonic Inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Other Mechanical Joining Techniques . . . . . . . . . . . . 44
Bonding with Adhesives. . . . . . . . . . . . . . . . . . . . . . . 44
Adhesive Choice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
TORLON Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Adhesive Application . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Curing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Bond Strength of Various Adhesives . . . . . . . . . . . . . . 45
Impact Strength of TORLON to TORLON Bonds . . . . . 45
Bonding for High-Temperature Applications . . . . . . . 45
Bonding TORLON parts to metal . . . . . . . . . . . . . . . . 46
Guidelines for Machining TORLON Parts. . . . . . . . . 47
Machined Parts Should be Recurred. . . . . . . . . . . . . . 47
Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Metallizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Electroplating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Flame/Arc Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Plasma Sputtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Ion Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Technical Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4
List of Tables
Room temperature tensile properties per ASTM D638· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Properties of TORLON molding resins at -321°F (-196°C) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Izod impact resistance for 1.8 inch (3.2 mm) samples · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Poly(amide-imide) balances fracture toughness and high glass transition temperature)· · · · · · · · · · ·
Thermal indices of TORLON resins · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
TORLON 4203L
Retention of properties after thermal aging · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Specific heat of TORLON polymers· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Thermal conductivity of TORLON resins · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Coefficients of linear thermal expansion for TORLON resins and selected metals.*· · · · · · · · · · · · · ·
Summary of flammability* data · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Chemical resistance of TORLON 4203L after 24 hour exposure at 200°F (93°C) except where noted otherwise.·
Property retention after immersion in 300°F (149°C) automotive lubricating fluid. · · · · · · · · · · · · · · ·
Tensile strength retention after immersion in aircraft hydraulic fluid4 · · · · · · · · · · · · · · · · · · · · ·
Percent change in properties of
TORLON 4203L with 2% absorbed water· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Important electrical considerations · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Electrical properties of TORLON resins · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Electrical resistance properties of TORLON 7130 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Attenuation in decibels and shielding effectiveness· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Thrust Washer Friction and Wear Test Method · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Wear characteristics of TORLON 4301 against various metals · · · · · · · · · · · · · · · · · · · · · · · · · ·
Wear characteristics of TORLON bearing grades using hardened C1018 steel as a reference · · · · · · ·
Lubricated wear resistance of TORLON 4301 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Specific strength and modulus of TORLON polymers
and selected metals · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Recommended maximum working stresses for injection molded TORLON resins · · · · · · · · · · · · · · ·
Wall thickness/insert o.d. relationship· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Strength of HeliCoil inserts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Strength of TORLON bolts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Shear strength of TORLON to TORLON bonds · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Shear strength* of TORLON to metal bonds· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Guidelines for machining TORLON parts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
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List of Figures
Structure of poly(amide-imide)· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7
TORLON resins have outstanding tensile strengths · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 12
Flexural strengths of TORLON resins are high across a broad temperature range · · · · · · · · · · · · · · · · · · · · · · · · · · · · 12
Tensile strengths of reinforced TORLON resins surpass competitive reinforced resins at 400°F (204°C). · · · · · · · · · · · · · · · 12
Flexural strengths of reinforced TORLON resins surpass competitive reinforced resins* at 400°F (204°C)· · · · · · · · · · · · · · · · · · 12
Flexural moduli of TORLON polymers · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 13
Flexural moduli of reinforced TORLON grades are superior to competitive reinforced resins* at 400°F (204°C) · · · · · · · · · · · · 14
Stress-strain in tension for TORLON resins at 73°F (23°C) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 14
Stress-strain in tension for TORLON resins at 275°F (135°C) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 14
Flexural fatique strength of TORLON resins at 30Hz · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 15
Tension/tension fatique strength of TORLON 7130 and 4203L, at 30Hz, A ratio: 0.90 · · · · · · · · · · · · · · · · · · · · · · · · · · · · 15
Tension/tension low cycle fatique strength of TORLON 7130, at 2Hz, A ratio: 0.90 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 15
High temperature flexural fatique strength of TORLON resins at 350°F (177°C), 30Hz · · · · · · · · · · · · · · · · · · · · · · · · · · · 15
Izod impact resistance of TORLON resins versus competitive materials* · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 16
Compact tension specimen · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 17
Thermogragimetric analysis of TORLON 4203L · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 18
TORLON resins retain strength after thermal aging at 482°F (250°C)· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 19
TORLON 4203L has superior property retention after thermal aging vs. competitive resins.* · · · · · · · · · · · · · · · · · · · · · · 19
Tensile strength· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 19
Tensile elongation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 19
Flexural modulus · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 19
Heat deflection temperature · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 19
Percent strain vs. time, 73°F (23°C)· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 21
Percent strain vs. time, 400°F (204°C) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 22
TORLON parts maintain high performance in hostile chemical environments. · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 24
Water absorption of TORLON polymers at 73°F (23°C), 50% relative humidity · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 26
Water absorption of TORLON polymers at 110°F (43°C), 90% relative humidity· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 26
Relative humidity determines equilibrium moisture absorption at room temperature · · · · · · · · · · · · · · · · · · · · · · · · · · · 26
Dimensional changes of TORLON polymers at 73°F (23°C), 50% relative humidity · · · · · · · · · · · · · · · · · · · · · · · · · · · · 26
Dimensional change of TORLON polymers at 110°F (43°C), 90% relative humidity · · · · · · · · · · · · · · · · · · · · · · · · · · · · 27
Thermal shock temperature versus moisture content of TORLON 4203L · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 27
Thermal shock temperature versus exposure time for TORLON 4203L · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 28
The elongation of TORLON 4203L is essentially constant after exposure to simulated weathering · · · · · · · · · · · · · · · · · · · 28
Change in tensile strength of TORLON 4203L with exposure to simulated weathering · · · · · · · · · · · · · · · · · · · · · · · · · · 28
Percent change in physical properties of TORLON 4203L after exposure to gamma radiation · · · · · · · · · · · · · · · · · · · · · · 28
Near field EMI shielding effectiveness, dual chamber method· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 30
Far field EMI shielding effectiveness, transmission line method · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 31
Material wear rate is a function of the Pressure-Velocity (PV) product· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 32
Wear resistance of TORLON resins compares to that of polyimide · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 33
Thurst washer test specimen · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 33
Extended cure at 500°F (260°C) improves wear resistance (cure cycles are a function of part geometry) · · · · · · · · · · · · · · · 35
Beam used in examples · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 38
Stress concentration factor for circular stress raiser (elastic stress, axial tension) · · · · · · · · · · · · · · · · · · · · · · · · · · · 39
Gradual blending between different wall thicknesses· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 40
Draft · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 40
Coring recommendations for TORLON parts. · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 41
Recommended rib sizes for TORLON parts. · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 41
6
Introduction
®
TORLON High Performance
Molding Polymers
TORLON grades, which can be divided into two categories; the high strength grades and the wear resistant
grades.
For reliable performance at extremely high temperature
and stress, use TORLON polymers. Parts made of TORLON
engineering polymers perform under conditions generally
considered too severe for thermoplastics. That’s why
parts for the space shuttle, the engine of a world-class
race car, and many other critical components have been
molded from TORLON polymers. Across a wide range of
industries-electrical and electronics; business equipment;
aerospace; transportation; process; and heavy equipment
— TORLON parts meet design challenges.
The high strength grades perform more like metals at elevated temperature, even under considerable stress.
These grades are ideally suited for repetitively-used precision mechanical and load bearing parts.
The inherent lubricity of TORLON poly(amide-imide) is enhanced with additives in the wear resistant grades.
Moving parts made of TORLON polymers provide dependable service in lubricated and non-lubricated environments.
Some other engineering resins may perform at 500°F, but
TORLON polymers maintain superior strength at this extreme temperature. Of the high-temperature plastics,
TORLON polymers have the advantage of being injection-moldable. That means exact replication and low unit
cost, making TORLON polymers the cost-effective solution
to difficult design problems.
TORLON engineering polymers
This manual introduces the reader to the TORLON polymer
family. Numerous graphs and tables present the physical
properties and load-bearing capabilities of TORLON polymers. A discussion of design guidelines and secondary
operations focuses on the practical aspects of fabricating
high-performance TORLON parts. Using this manual, the
designer can relate the characteristics of these exceptional resins to his own specific needs.
High strength
Wear resistant
4203L
4347
5030
4301
7130
4275
Only TORLON Engineering Polymers Offer a Combination of:
· Performance from cryogenic to 500°F
· Outstanding mechanical strength
· Easy fabrication
· Low flammability and smoke generation
Solvay Advanced Polymers’ TORLON high performance
polymer is a poly(amide-imide), with the general structure:
· Fatigue strength
Figure 1
· Creep resistance
Structure of poly(amide-imide)
· Wear resistance
· Impact strength
· Low expansion coefficients
· Excellent thermal stability
· Resistance to aviation and automotive fluids
The variety of applications requiring high temperature resistance, high strength, and the economies of injection-molding has led to the commercialization of several
–7–
TORLON EngineeringPolymers Design Manual
The High Performance TORLON Polymers
Introduction
TORLON poly(amide-imide) resins are injection-moldable
thermoplastics that offer truly outstanding performance.
Diversity of end-use applications has led to development
of several grades, each designed to maximize specific
properties.
If your application requires a special modified grade, we
can compound TORLON polymers to your specifications.
This page describes the TORLON family and suggests
general application areas. For specific advice concerning
a particular application, please contact your Solvay Advanced Polymers representative.
TORLON
grade
Nominal composition
Description of properties
Applications
4203L
3%
1 %
2
TiO2
fluorocarbon
Best impact resistance, most elongation, and
good mold release and electrical properties.
Connectors, switches, relays, thrust washers,
spline liners, valve seats, poppets, mechanical
linkages, bushings, wear rings, Insulators, cams,
picker fingers, ball bearings, rollers, and thermal
insulators.
5030
30%
1%
glass fiber
fluorocarbon
High stiffness, good retention of stiffness at
elevated temperature, very low creep, and high
strength.
Burn-in sockets, gears, valve plates, fairings,
tube clamps, impellers, rotors, housings,
back-up rings, terminal strips, insulators, and
brackets.
7130
30%
1%
graphite fiber
fluorocarbon
Similar to 5030 but higher stiffness. Best
retention of stiffness at high temperature, best
fatigue resistance. Electrically conductive.
Metal replacement, housings, mechanical
linkages, gears, fasteners, spline liners, cargo
rollers, brackets, valves, labyrinth seals, fairings,
tube clamps, standoffs, impellers, shrouds,
potential use for EMI shielding.
4347
12%
8%
graphite powder
fluorocarbon
Good for reciprocating motion or bearings
subject to high loads at low speeds. Best wear
resistance.
Bearings, thrust washers, wear pads, strips,
piston rings, and seals.
4301
12%
3%
graphite powder
fluorocarbon
Similar to 4347. Designed for bearing use. Good
wear resistance, low coefficient of friction, and
high compressive strength.
piston rings, seals, vanes, and valve seats.
4275
20%
3%
graphite powder
fluorocarbon
Similar to 4301 with better wear resistance at
high speeds.
piston rings, seals, vanes, and valve seats.
High strength
Wear Resistant
–8–
Physical Properties
Physical Properties
High impact strength, exceptional mechanical strength,
and excellent retention of these properties in high temperature environments characterize all TORLON resins.
At room temperature, tensile and flexural strengths of
TORLON 4203L are about twice those of standard engineering resins such as polycarbonate and nylon. At 500°F
(260°C), tensile and flexural strengths of TORLON 4203L
are almost equal to these engineering resins at room temperature. Superior physical properties are retained after
long-term exposure to elevated temperature.
These physical properties are typical of injection molded,
post-cured test specimens.
Footnotes for Typical Property Tables on Pages 10 and 11.
(1) Tensile properties per ASTM D638 appear on Page 13.
(2) Note: The test methods used to obtain these date measure response to
heat and flame under controlled laboratory conditions and may not provide
an accurate measure of the hazard under actual fire conditions.
*
–9–
By this test, this grade is conductive. See discussion on page 29.
Typical Properties – US Units
Properties
Mechanical
Tensile Strength(1)
-321°F
73°F
275°F
450°F
Tensile Elongation
-321°F
73°F
275°F
450°F
Tensile Modulus
73°F
Flexural Strength
-321°F
73°F
275°F
450°F
Flexural Modulus
-321°F
73°F
275°F
450°F
Compressive Strength
Compressive Modulus
Shear Strength
73°F
Izod Impact Strength ( 18 in)
notched
unnotched
Poisson’s Ratio
Thermal
Deflection Temperature
264 psi
Coefficient of Linear Thermal
Expansion
Thermal Conductivity
Flammability(2), Underwriters’
Laboratories
Limiting oxygen index(2)
Electrical
Dielectric constant
103 Hz
106 Hz
Dissipation factor
103 Hz
106 Hz
Volume resistivity
Surface resistivity
Dielectric strength (0.040 in)
General
Density
Hardness, Rockwell E
Water absorption
10
ASTM Test
Method
Units
D1708
kpsi
D1708
105 psi
D790
kpsi
4275
4347
5030
7130
31.5
27.8
16.9
9.5
23.7
16.3
10.6
18.8
22.0
16.9
8.1
17.8
15.1
7.8
29.5
29.7
23.1
16.3
22.8
29.4
22.8
15.7
6
15
21
22
7
20
17
3
7
15
17
9
21
15
4
7
15
12
3
6
14
11
7.0
9.5
11.3
8.7
15.6
32.2
41.0
34.9
24.8
17.1
31.2
23.5
16.2
29.0
30.2
22.4
15.8
27.0
20.5
14.3
54.4
48.3
35.9
26.2
45.0
50.7
37.6
25.2
10.0
7.9
7.2
24.1
7.7
13.9
10.6
8.1
7.4
17.8
5.8
9.1
6.4
6.2
18.3
20.4
17.0
15.5
14.3
38.3
11.5
35.7
28.8
27.2
22.8
36.9
14.3
18.5
16.1
11.1
11.5
20.1
17.3
2.7
20.0
0.45
1.2
7.6
0.39
1.6
4.7
0.39
1.3
1.5
9.5
0.43
0.9
6.4
0.39
532
534
536
532
539
540
14
15
9
5
2.5
3.6
105 psi
D695
D695
D732
kpsi
105 psi
kpsi
D256
ft•lbs/in
D648
4301
%
D1708
D790
4203L
11.4
7.3
5.6
5.2
32.1
°F
D696
10-6 in/in°F
17
14
C177
Btu in/hr ft 2°F
1.8
3.7
94 V-0
94 V-0
94 V-0
94 V-0
94 V-0
94 V-0
45
44
45
46
51
52
4.2
3.9
6.0
5.4
7.3
6.6
6.8
6.0
4.4
4.2
*
*
0.026
0.031
8 x 1016
5 x 1018
580
0.037
0.042
3 x 1015
8 x 1017
0.059
0.063
3 x 1015
4 x 1017
0.037
0.071
3 x 1015
1 x 1018
0.022
0.050
6 x 1016
1 x 1018
840
*
*
*
*
*
0.051
86
0.33
0.053
72
0.28
0.054
70
0.33
0.054
66
0.17
0.058
94
0.24
0.054
94
0.26
D2863
%
D150
D150
D257
D257
D149
ohm-in
ohm
V/mil
D792
D785
D570
lb/in3
%
Typical Properties – SI Units
Properties
Mechanical
Tensile Strength(1)
-196°C
23°C
135°C
232°C
Tensile Elongation
-196°C
23°C
135°C
232°C
Tensile Modulus
23°C
Flexural Strength
-196°C
23°C
135°C
232°C
Flexural Modulus
-196°C
23°C
135°C
232°C
Compressive Strength
Compressive Modulus
Shear Strength
23°C
Izod Impact Strength (3.2 mm)
notched
unnotched
Poisson’s Ratio
Thermal
Deflection Temperature
1.82 MPa
Coefficient of Linear
Thermal Expansion
Flammability(2), Underwriters
Laboratories
Limiting Oxygen Index(2)
Electrical
Dielectric Constant
103 Hz
106 Hz
Dissipation Factor
103 Hz
106 Hz
Volume Resistivity
Surface Resistivity
Dielectric Strength (1 mm)
General
Density
Hardness, Rockwell E
Water Absorption
11
ASTM Test
Method
Units
D1708
MPa
D1708
GPa
D790
MPa
MPa
GPa
MPa
D256
J/m
D696
C177
4347
5030
7130
218
192
117
66
164
113
73
130
152
113
56
123
104
54
204
205
160
113
158
203
158
108
6
15
21
22
7
20
17
3
7
15
17
9
21
15
4
7
15
12
3
6
14
11
4.9
6.6
7.8
6.0
10.8
22.3
287
244
174
120
219
165
113
203
212
157
111
189
144
100
381
338
251
184
315
355
263
177
7.9
5.0
3.9
3.6
220
4.0
6.9
5.5
4.5
170
5.3
9.6
7.3
5.6
5.1
120
6.3
4.4
4.3
130
14.1
11.7
10.7
9.9
260
7.9
24.6
19.9
18.8
15.7
250
9.9
128
112
77
80
140
120
142
1062
0.45
63
404
0.39
84
250
0.39
69
79
504
0.43
47
340
0.39
278
279
280
278
282
282
30.6
0.26
25.2
0.54
25.2
27.0
16.2
0.37
9.0
0.53
94 V-0
94 V-0
94 V-0
94 V-0
94 V-0
94 V-0
45
44
45
46
51
52
4.2
3.9
6.0
5.4
7.3
6.6
6.8
6.0
4.4
4.2
*
*
0.026
0.031
2 x 1015
5 x 1018
23.6
0.037
0.042
8 x 1013
8 x 1017
0.059
0.063
8 x 1013
4 x 1017
0.037
0.071
8 x 1013
1 x 1018
0.022
0.050
2 x 1015
1 x 1018
32.6
*
*
*
*
*
1.42
86
0.33
1.46
72
0.28
1.51
70
0.33
1.50
66
0.17
1.61
94
0.24
1.48
94
0.26
°C
10-6 m/m/°C
W/mK
UL94
D2863
4275
GPa
D695
D695
D732
D648
4301
%
D1708
D790
4203L
%
D150
D150
D257
D257
D149
ohm-m
ohm
kV/mm
D792
D785
D570
g/cm3
%
Tensile and Flexural Strength at Temperature Extremes
Performance Properties
Ultra High Temperature
TORLON poly(amide-imide) can be used in applications
previously considered too demanding for many other engineering plastics because of its outstanding tensile and
flexural strength combined with retention of these properties in continuous service at temperatures in excess of
450°F (232°C).
While many competitive resins can claim “excursions” up
to 500°F (260°C), TORLON polymers function with integrity
at extremely high temperatures, as shown by Figures 2
and 3, which demonstrate the exceptional retention of
tensile and flexural strength of TORLON resins at elevated
temperatures.
60
400
MPa
300
40
200
20
100
0
0
100
200
300
Temperature, °F
0
500
400
Figure 4
Tensile strengths of reinforced TORLON resins surpass competitive reinforced resins at 400°F (204°C).
20
Even at 400°F (204°C), the strengths in both tensile and
flexural modes of TORLON engineering polymers are
better than other high performance engineering resins.
Figures 4 and 5 compare reinforced TORLON polymers to
other high performance reinforced resins.
125
15
100
75
10
MPa
Tensile and Flexural Strength at Temperature Extremes
Flexural strengths of TORLON resins are high
across a broad temperature range
Flexural Strength, kpsi
Mechanical Properties
Figure 3
Tensile Strength, kpsi
The unrivaled properties of TORLON engineering polymers
meet the requirements of the most demanding applications. Strength retention over a wide range of temperatures and sustained stress, low creep, flame resistance,
outstanding electrical properties, and exceptional integrity in severe environments place TORLON poly(amide-imide) in a class by itself among engineering resins.
50
5
0
25
TORLON
7130
TORLON
5030
RADEL
AG-330
KADEL
E-1130
Ultem
2300
Ryton
R-4
Vespel
SP-1
0
Figure 2
Figure 5
TORLON resins have outstanding tensile strengths
Flexural strengths of reinforced TORLON resins surpass
competitive reinforced resins* at 400°F (204°C)
200
100
10
50
0
0
100
200
300
400
0
500
Temperature, °F
*
250
30
– 12 –
150
20
100
10
0
Ultem is a registered trademark of General Electric Company.
Ryton is a registered trademark of Phillips Petroleum Company.
Vespel is a registered trademark of E.I. DuPont de Nemours and Company.
200
50
TORLON
7130
TORLON
5030
RADEL
AG-330
KADEL
E-1130
Ultem
2300
Ryton
R-4
Vespel
SP-1
0
MPa
20
Flexural Strength, kpsi
40
150
MPa
30
Mechanical Properties
Flexural Modulus-Stiffness at High Temperature
Tensile Properties Per ASTM D638
Ultra Low Temperature
Tensile properties reported in the preceding section were
the result of ASTM D1708 testing. Since ASTM D638 is frequently referenced, TORLON polymers were also tested in
accordance with this method.
The data appear in Table 1.
At the other end of the temperature spectrum, TORLON
polymers do not become brittle as do other resins. Table 2
shows TORLON resins have excellent properties under
cryogenic conditions.
Table 2
Properties of TORLON molding resins at -321°F (-196°C)
Table 1
TORLON grade
Room temperature tensile properties per ASTM D638
Tensile
strength,
TORLON grade
4203L
4301
4275
4347
5030
7130
22.0
16.4
16.9
16.2
32.1
36.2
MPa
152
113
117
112
221
250
Elongation,
%
7.6
3.3
2.6
3.5
2.3
1.2
Tensile
modulus,
kpsi
650
990
1,280
1,040
2,110
3,570
GPa
4.5
6.8
8.8
7.2
14.6
24.6
%
4275
7130
5030
31.5
(216)
18.8
(129)
22.8
(157)
29.5
(203)
6
3
3
4
Flexural
strength,
kpsi
(MPa)
41.0
(282)
29.0
(200)
45.0
(310)
54.4
(374)
Flexural
modulus,
kpsi
(GPa)
1,140
(7.8)
1,390
(9.6)
3,570
(24.6)
2,040
(14.0)
Flexural Modulus-Stiffness at High Temperature
TORLON poly(amide-imide) has high modulus, making it a
good replacement for metal where stiffness is crucial to
performance. TORLON parts can provide equivalent stiffness at significantly lower weight. Excellent retention of
part stiffness and resistance to creep or cold flow is predicted from the high and essentially constant modulus of
TORLON resins, even at 45°F (232°C), as shown in Figure
6. Unlike competitive materials, which lose stiffness at
higher temperatures, TORLON polymers have high moduli
at elevated temperatures, as Figure 7 demonstrates.
Figure 6
Flexural moduli of TORLON polymers
3
20
15
2
10
1
5
0
0
– 13 –
GPa
kpsi
Flexural Modulus, Mpsi
Tensile
Strength,
Elongation
at break,
kpsi
(MPa)
4203L
100
200
300
400
0
500
Stress-Strain Relationship
Figure 9
Flexural moduli of reinforced TORLON grades are superior to competitive reinforced resins* at 400°F
(204°C)
Stress-strain in tension for TORLON resins at
275°F (135°C)
15
10
1.5
1
5
0.5
0
TORLON
7130
RADEL
AG-330
TORLON
5030
Ultem
2300
Ryton
R-4
0
Stress-Strain Relationship
Stress-strain in tension for TORLON resins at 73°F (23°C)
30
3L
420
ON
L
R
TO
150
100
MPa
20
N
71
30
15
LO
TO
R
Tensile Stress kpsi
TOR
LON
7130
TO
RLO
N5
030
200
10
TO
5
O
RL
N
50
30
50
3L
420
LON
TOR
0
0
0
5
75
N
LO
R
TO
5
30
50
50
L
4203
ON
L
R
TO
25
0
0
Figure 8
0
10
0
TORLON poly(amide-imide) does not yield at room temperature, therefore, strain at failure or rupture is recorded as
the elongation. Figures 8 and 9 show the stress-strain relationship for TORLON grades at room temperature and
275°F (135°C). Figure 9 and the inset in Figure 8 highlight
the nearly linear (“Hookean”) portion of the curve.
10
71
30
2
100
TO
RL
ON
Tensile Stress, kpsi
15
0.25
10
0.5
0.75
1
0
15
Strain, %
– 14 –
0.25
0.5
Strain, %
0.75
1
MPa
2.5
GPa
Flexural Modulus, Mpsi
Figure 7
Resistance To Cyclic Stress
Fatigue Strength
temperature. The results, shown in Figure 13, suggest
TORLON polymers are suitable for applications requiring
fatigue resistance at high temperature.
Figure 11
Tension/tension fatique strength of TORLON 7130 and
4203L, at 30Hz, A ratio: 0.90
S-N diagrams, showing maximum stress versus cycles to
failure, are useful in predicting product life. The maximum
stress using the anticipated force, appropriate stress concentration factors, and section modulus is determined.
The maximum stress is then compared to the fatigue
strength S-N curve for the applicable environment to determine the maximum cyclic stress the material can be
expected to withstand.
200
25
175
150
20
125
15
100
10
75
50
05
0
25
0
103
104
105
106
107
Cycles to Failure
Figure 12
Tension/tension low cycle fatique strength of
TORLON 7130, at 2Hz, A ratio: 0.90
Maximum Stress, kpsi
The values obtained in fatigue testing are influenced by
the specimen and test method; therefore, the values
should serve as guidelines, not absolute values. TORLON
parts resist cyclic stress. TORLON 7130, a graphite fiber
reinforced grade, has exceptional fatigue strength, and is
superior to competitive engineering resins. Figure 10, the
S-N curves for selected TORLON grades, shows that even
after 10,000,000 cycles, TORLON poly(amide-imide) has
excellent resistance to cyclical stress in the flexural
mode, and Figure 11 demonstrates the integrity of
TORLON 7130 under tension/tension cyclical stress. At
lower frequencies, the fatigue strength of TORLON 7130 is
even higher, as shown in Figure 12.
30
MPa
When a material is stressed cyclically, failure will occur at
stress levels lower than the material’s ultimate strength.
Resistance to failure under cyclical loading or vibration,
called fatigue strength, is an important design consideration. TORLON engineering polymers offer excellent fatigue strength in both the tensile mode and the very severe flexural mode, a form of reverse bending.
30
200
25
175
150
20
125
15
100
10
75
MPa
Fatigue Strength
50
05
Even at high temperature, TORLON polymers maintain
strength under cyclic stress. Flexural fatigue tests were
run at 350°F (177°C) on specimens preconditioned at that
0
25
0
103
104
105
106
107
Cycles to Failure
Figure 10
Figure 13
Flexural fatique strength of TORLON resins at 30Hz
High temperature flexural fatique strength of
TORLON resins at 350°F (177°C), 30Hz
75
10
50
5
25
0
0
3
10
4
10
5
10
6
10
15
Cycles to Failure
75
10
50
5
25
0
7
10
100
MPa
100
MPa
15
0
103
104
105
106
107
Cycles to Failure
– 15 –
Impact Resistance
Impact Resistance
TORLON resins absorb impact energy better than most
high modulus plastics. In tests using the notched Izod
method (ASTM D256), TORLON resins give results superior to those of other high temperature resins (Figure 14).
Table 3 summarizes both notched and unnotched impact
data for TORLON resins.
Table 3
Izod impact resistance for 1.8 inch (3.2 mm) samples
TORLON grade
Notched
Unnotched
ft•lb/in
J/m
ft•lb/in
J/m
4203L
2.7
142
20.0
1062
4301
1.2
63
7.6
404
4275
1.6
84
4.7
250
4347
1.3
69
—
—
5030
1.5
79
9.5
504
7130
0.9
47
6.4
340
Figure 14
4
200
3
150
2
100
1
50
0
*
TORLON
4203L
TORLON
5030
TORLON
4275
Vespel
SP-1
Ryton
R-4
Vespel
SP-21
Ultem
1000
RADEL
A-300
J/m
Notched Izod, ft-lbs/in
Izod impact resistance of TORLON resins
versus competitive materials*
0
Ultem is a registered trademark of General Electric Company
Ryton is a registered trademark of Phillips Petroleum Company
Vespel is a registered trademark of E.I. DuPont de Nemours and Company
– 16 –
Fracture Toughness
Fracture Toughness
Fracture toughness can be assessed by measuring the
fracture energy (Glc) of a polymer. The Naval Research
Laboratory (NRL) uses a compact tension specimen
(Figure 15) to determine Glc a measure of a polymer’s
ability to absorb and dissipate impact energy without fracturing — larger values correspond to higher fracture
toughness. Table 4 shows selected data from NRL Memorandum Report 5231 (February 22,1984). As expected, thermosetting polymers cannot absorb and dissipate impact
energy as well as thermoplastics and consequently have
lower fracture energies. TORLON poly(amide-imide) exhibits outstanding fracture toughness, with a Glc of 1.6
ft b/in 2 (3.4 kJ/m2). Glass transition temperatures (Tg) are
included in the table to indicate the tradeoff between
fracture toughness and useful temperature range.
Poly(amide-imide) is characterized by a balance of toughness and high Tg.
Table 4
Figure 15
Poly(amide-imide) balances fracture toughness and
high glass transition temperature)
Fracture energy
Tg
ft•lb/in2
kJ/m2
°F
°C
Polyimide-1
0.095
0.20
662
350
Polyimide-2
0.057
0.12
680
360
Tetrafunctional epoxy
0.036
0.076
500
260
Thermosets
Thermoplastics
Poly(amide-imide)
1.6
3.4
527
275
Polysulfone
1.5
3.1
345
174
Polyethersulfone
1.2
2.6
446
230
Polyimide-4
1.0
2.1
689
365
Polyimide-3
0.38
0.81
619
326
Polyphenylene sulfide
0.10
0.21
—
—
Compact tension specimen
a
b
W
2
GIC =
Y 2Pc a
EW 2 b 2
Where:
Y = 29.6 - 186 (a/w) + 656 (a/w)2 - 1017 (a/w)3 + 639 (a/w)4
P = critical fracture load
a = crack length
E = sample modulus
c
– 17 –
Thermogravimetric Analysis
Thermal Stability
Table 5
Thermal indices of TORLON resins
Thermogravimetric Analysis
Electrical
TORLON resins are exceptionally stable over a wide range
of temperatures. When heated at a rate of 18°F (10°C) per
minute in air or nitrogen atmospheres, TORLON 4203L
shows virtually no weight loss over its normal service
temperatures and well beyond, as shown in Figure 16.
Minimum
thickness
Mechanical
With
impact
Without
impact
in
mm
°F
°C
°F
°C
°F
°C
0.031
0.79
428
220
*
*
410
210
Figure 16
0.046
1.17
428
220
*
*
410
210
Thermogragimetric analysis of TORLON 4203L
0.096
2.44
428
220
*
*
410
210
0.120
3.05
428
220
392
200
428
220
TORLON 4301 0.120
3.05
*
*
392
200
392
200
TORLON 5030 0.062
1.58
428
220
*
*
*
*
0.096
2.44
428
220
*
*
*
*
0.120
3.05
428
220
392
200
428
200
TORLON
4203L
Temperature, °C
100
200
300
400
500
600
700
800
900
100
Weight retained, %
90
*Specimen not tested
80
70
*Initial properties, including tensile strength, impact strength, dielectric
strength, arc resistance, dimensional stability, and flammability, are
determined for the test material. For each property and each aging
temperature, a record is kept of elapsed time and the change in that
property as a percent of initial. The “end-of-life” for a property is the time
required at the aging temperature to reach 50 percent of initial. End- of-life
points are plotted and regression applied to predict “life expectancy” at
any operating temperature. The thermal index is that temperature at which
life expectancy is 100,000 hours. TORLON polymers were tested in
accordance with the above procedure for 50 percent degradation of
dielectric strength (Electrical), lzod impact (Mechanical-with impact), and
tensile strength (Mechanical-without impact). The other properties did not
change significantly.
Nitrogen
60
50
40
30
20
Air
10
0
0
500
1,000
1,500
Temperature, °F
Retention of Properties After Thermal Aging
Effects of Prolonged Thermal Exposure
Ul Thermal Index
The UL Thermal index provides an estimate of the maximum continuous use temperature and is defined by the
method prescribed by Underwriters Laboratories’. The UL
thermal index predicts at least 100,000 hours of useful life
at the index temperature. TORLON polymers have UL thermal indices as high as 220°C, which is equivalent to more
than eleven years of continuous use at 428°F, and is significantly higher than most high-temperature engineering
resins. Table 5 summarizes the thermal indices of TORLON
4203L, 4301, and 5030.
TORLON poly(amide-imide) resists chemical breakdown
and retains high strength after prolonged thermal exposure. One method for determining the thermal stability of
polymers is to measure mechanical properties of samples
after aging at elevated temperatures* TORLON resins retain strength after long-term aging at high temperature, as
shown in Figure 17. After 10,000 hours, tensile strengths of
TORLON polymers exceed the ultimate strength of many
competitive resins. TORLON 4203L, for example, still has
tensile strength of over 25,000 psi. It is interesting to note
that the specimens actually increase in tensile strength
initially, because even greater strength is attained beyond
the standard post cure.
*
– 18 –
Injection molded and post-cured tensile bars (ASTM D1708 configuration,
1 inch thick) were aged in forced air ovens at 482°F (250°C). Specimens
8
were periodically removed from the ovens, conditioned at 73°F (23°C) and
50 percent relative humidity then tested for tensile strength.
Thermal Stability
Retention of Properties After Thermal Aging
Figure 17
Figure 18B
TORLON resins retain strength after thermal aging at
482°F (250°C)
Tensile elongation
Tensile Strengthm 103 psi
40
TORLON 4203L
200
20
TORLON 43
01
100
10
40
30
20
0
100
0
3000
1000
300
10000
10
00
(4
00
4203L (500°F)
°FTORLON
)
10
30000
Victrex PES 200P (400°F)
Time, Hours
250
1000
750
Hours aged
Figure 18C
Flexural modulus
8
Flexural modulus, 105 psi
Compared with other non-reinforced high temperature engineering polymers, TORLON 4203L demonstrates superior
thermal stability. Figures 18A through D show the results
of a 1,000 hour thermal aging study. The resins were aged
at temperatures within 30°F (17°C) of their glass transition
temperatures to avoid phase change. Tensile strength,
elongation, flexural modulus, and heat deflection of
TORLON 4203L changed very little, while one competitive
resin showed significant loss of elongation.
500
TORLON 420
3L (
5 0 0° F)
5
6
4
Ultem 1000 (40
0°F)
Victrex PES 200P (400°F)
4
3
103 N/m2
TORLON 5030
MPa
30
50
m
te
Ul
60
2
2
1
Figure 18A—D
TORLON 4203L has superior property retention after
thermal aging vs. competitive resins.*
250
500
750
Hours aged
Resins were aged at temperatures noted in parenthesis.
Figure 18A
Figure 18D
Tensile strength
Heat deflection temperature
600
TORLON 4203L (50
0°F)
200
150
20
Ultem 1000 (400 °F)
S 200P (400°F)
Victrex PE
100
10
300
500
250
ES 200P (400°F)
Victrex P
400
Ultem 1000 (400°F
)
200
°C
Heat deflection temperature, °F
TORLON 4203L ( 50 0 ° F)
N/mm2
Tensile Strengthm 103 psi
30
1000
300
150
200
100
100
50
50
250
500
750
1000
250
500
750
1000
Hours aged
Hours aged
– 19 –
Specific Heat
TORLON polymers maintain exceptional electrical and
mechanical properties and UL flammability ratings after
long-term heat aging. Table 6 demonstrates that TORLON
4203L is still suitable for demanding applications even after extended exposure to 482°F (250°C).
Table 8
Thermal conductivity of TORLON resins
Thermal conductivity
Btu•in/hr•ft2•°F
W/m•K
TORLON 4203L
1.8
0.26
TORLON 4301
3.7
0.54
TORLON 5030
2.5
0.37
TORLON 7130
3.6
0.53
Table 6
TORLON 4203L
Retention of properties after thermal aging
Sample
thicknes
s
Property
Hours at 480°F (250°C)
2,000
in (mm)
0.035
(0.9)
12,000
Dielectric strength, V/mil
(kV/mm)
17,000
654
1
8
(3.2) Flammability, UL 94
94 V-0
94 V-0
94 V-0
1
8
(3.2) Dimensional change, %
0.0
0.5
0.9
1
8
(3.2) Tensile strength retained, % 110
86
67
Metal-Like Coefficients of Linear Thermal Expansion
The thermal expansion of filled TORLON poly(amide-imide)
nearly matches that of common metals. In Table 9, we
have expressed the expansion coefficients of TORLON
resins on the order of 106 because this is the order of
magnitude generally used for metals.
Specific Heat
Specific heat as a function of temperature was determined using a differential scanning calorimeter
The data for four TORLON grades at four temperatures
are presented in Table 7.
Table 9
Coefficients of linear thermal expansion for TORLON
resins and selected metals.*
Table 7
CLTE
Specific heat of TORLON polymers
-6
10 in/in•°F
Specific heat, cal/gm°C
TORLON grade
4203L
Temperature, °F (°C)
77 (25)
0.242
212 (100)
0.298
4301
5030
7130
0.240
0.298
0.229
0.276
0.230
0.285
TORLON resins have low thermal conductivity, and are
suitable for applications requiring thermal isolation.
TORLON heat shields protect critical sealing elements
from high temperatures, and protect sensitive instrument
elements from heat loss. Table 8 shows the thermal conductivity of TORLON resins using ASTM C177.*
*
ASTM C177 utilizing 0.06 inch (1.6 mm) thick specimens with cold plate
temperature of 122°F (50°C) and hot plate temperature of 212°F (100°C).
TORLON 7130
5
Inconel X, annealed
6.7
12.1
Plain carbon steel AISI-SAE 1020
6.7
12.1
Titanium 6-2-4-2
7
12.6
TORLON 5030
9
16.2
Copper
9.3
16.7
Stainless steel, type 304
9.6
17.3
Commercial bronze, 90%, C2200
10.2
18.4
Aluminum alloy 2017, annealed, ASTM
B221
12.7
22.9
TORLON 4275
14
25.2
TORLON 4301
14
25.2
Aluminum alloy 7075
14.4
26.0
TORLON 4347
15
27.0
TORLON 4203L
17
30.6
*
– 20 –
mm/m•K
9.0
CLTE data for TORLON resins were determined per ASTM D696, over a
temperature range of 75-3~”0”°F (24-149”C). CLTE data for metals are from
t he CRC Handbook of Chemistry and Physics, 54th ed. and Materials
Engineering, 1984 Materials Selector edition, Dec. 1983.
Thermal Stability
Creep Resistance
Creep Resistance
Figure 19C
5
TORLON 4301
73°F (23°C)
4
Percent strain
A limitation of most plastics is deformation under stress,
commonly called creep. TORLON poly(amide-imide) resists creep, and handles stress more like a metal than a
plastic. To get measurable creep, TORLON polymer must
be stressed beyond the ultimate strength of most other
plastics. The designer must consider the long-term creep
behavior of plastics under the expected stress and temperature conditions of the proposed application. Figures
19A through N summarize selected data from tensile
creep tests (ASTM D2990) at applied stress of 5,000,
10,000, and 15,000 psi (34.5, 69.0, and 103.4 N/mm2).
Non-reinforced TORLON grades may creep or rupture at
extremely high temperatures (over 400F) when stress exceeds 5,000 psi (34.5 N/mm2). For these applications, a reinforced grade is recommended.
3
15,000 psi
2
10,000 psi
1
5000 psi
0
0.01
0.10
1.00
10
100
10
100
10
100
10
100
Time, hours
Figure 19D
5
Figure 19A—F
TORLON 4347
73°F (23°C)
4
Percent strain
Percent strain vs. time, 73°F (23°C)
Figure 19A
15,000 psi
3
2
10,000 psi
5
1
TORLON 4203L
73°F (23°C)
Percent strain
4
5000 psi
0
15,000 psi
0.01
0.10
Time, hours
Figure 19E
10,000 psi
2
5
5000 psi
1
TORLON 5030
73°F (23°C)
4
0
0.10
1.00
10
100
Percent strain
0.01
Time, hours
3
2
15,000 psi
10,000 psi
5000 psi
1
Figure 19B
0
5
0.01
TORLON 4275
73°F (23°C)
4
0.10
psi
1 5,00 0
3
5
TORLON 7130
73°F (23°C)
4
2
10,000 psi
1
5000 psi
0
0.01
0.10
1.00
1.00
Time, hours
Figure 19F
Percent strain
Percent strain
1.00
3
10
3
2
100
1
Time, hours
15,000 psi
10,000 psi
5000 psi
0
0.01
0.10
1.00
Time, hours
– 21 –
Creep Resistance
Figure 19H-M
Percent strain vs. time, 400°F (204°C)
Figure 19H
Figure 19K
5
5
TORLON 4203L
400°F (204°C)
TORLON 4347
400°F (204°C)
4
Percent strain
Percent strain
4
3
2
3
2
5000 psi
1
5000 psi
1
0
0
0.01
0.10
1.00
10
100
0.01
0.10
Time, hours
1.00
10
100
10
100
10
100
Time, hours
Figure 19L
Figure 19I
5
5
TORLON 5030
400°F (204°C)
TORLON 4275
400°F (204°C)
4
Percent strain
Percent strain
4
3
2
1
3
2
1 0,000 psi
1
5000 psi
5000 psi
0
0
0.01
0.10
1.00
10
100
0.01
0.10
Time, hours
Time, hours
Figure 19J
Figure 19M
5
5
TORLON 4301
400°F (204°C)
TORLON 7130
400°F (204°C)
4
Percent strain
4
Percent strain
1.00
3
2
1
3
2
1
5000 psi
10,000 psi
5000 psi
0
0
0.01
0.10
1.00
10
100
0.01
Time, hours
0.10
1.00
Time, hours
– 22 –
Flammability
Summary of Flammability Data
Flammability
Test data indicate the suitability of TORLON parts for electrical, electronic, aerospace, and other applications
where flammability is of great concern. TORLON 5030 and
7130 exceed FAA requirements for flammability, smoke
density, and toxic gas emission, and surpass, by a large
margin, the proposed requirements for aircraft interior
use.
Summary of Flammability Data
The results of several laboratory tests designed to measure the burning characteristics of materials are shown in
Table 10.
The tests show that TORLON resins are extremely resistant to flame, and are characterized by low smoke
generation.
5. Vertical Flammability Class by Underwriters Laboratories (UL 94)
94 V-0 ratings for
Thickness
TORLON grades
in.
mm
0.008
0.20
4203L
0.020
0.51
4203L
0.046
1.17
4203L, 4301, 5030
0.058
1.47
4203L, 4301, 5030
0.096
2.44
4203L, 4301
0.120
3.05
4203L, 4301
0.125
3.18
All TORLON grades
6. Vertical flammability, FAA Transport Category Airplanes, 25.853 (a)
and Appendix F.
Table 10
Summary of flammability* data
TORLON 5030
TORLON 7130
1. Oxygen Index, ASTM D2863
TORLON 4203L
TORLON 4301
TORLON 4275
TORLON 4347
TORLON 5030
TORLON 7130
Oxygen Index, %
45
44
45
46
51
52
Samples of TORLON 5030 and 7130 were also tested for horizontal
flammability (FAA Transport Category Airplanes, 25.853(b-3) and Appendix
F) and 45 flammability (FAA Cargo and Baggage Compartment, 25.855(1-a)).
In both cases, the test specimens did not ignite. Based on that result,
TORLON 5030 and 7130 meet the requirements of these codes.
7. Flammability requirements in accordance with Underwriters Laboratories
“Electric Lighting Fixtures” (UL 57)
Noncombustible by Section 81.12. for
TORLON 4203L
thickness of 0.040, 0.125 and 0.200 inches
(1. 0 2, 3.18, 5.08 mm)
2. FAA Smoke Density, National Bureau of Standards,
NFPA 258. Specimen thickness 0.05-0.06 inch (1.3-1.5 mm)
TORLON
4203L
TORLON
5030
Sm
Sm
Minimum light
92
transmittance (Tm), %
Maximum specific optical
5
density (Dm)
18.5
Time to 90% Dm, minutes
Sm= Smoldering, Fl = Flaming
Fl
Fl
Average burn length
in.
mm
0.6
15.2
0.6
15.2
TORLON 7130
Sm
Note: The test methods used to obtain these data measure response to heat
and flame under controlled laboratory conditions detailed in the test
method specified and may not provide an accurate measure of fire hazard
under actual fire conditions. Furthermore, as Solvay Advanced Polymers
has no control over final formulation by the user of these resins including
components incorporated either internally or externally, nor over
processing conditions or final physical form or shape, these results may
not be directly applicable to the intended end use.
Fl
6
96
56
95
28
170
2
35
3
75
18.6
10.7
15.7
17.0
16.0
3. FAA Toxic Gas Emission Test,
National Bureau of Standards, NFPA 258.
Specimen thickness 0.05-0.06 inch (1.3-1.5 mm).
TORLON 5030
Sm
Fl
ppm
ppm
Hydrochloric acid
0
<1
Hydrofluoric acid
0
0
Carbon monoxide
<10
120
Nitrogen oxides
<2
19
Hydrocyanic acid
0
4
Sulfur dioxide
0
0
Sm= Smoldering, Fl = Flaming
TORLON 7130
Sm
Fl
ppm
ppm
0
<1
0
0
<10
100
0
14
0
5
0
4
– 23 –
Chemical Resistance
Performance in Various
Environments
Table 11
Chemical resistance of TORLON 4203L after 24 hour exposure at 200°F (93°C) except where noted otherwise.
Chemical Resistance
TORLON poly(amide-imide) is virtually unaffected by
aliphatic and aromatic hydrocarbons, chlorinated and fluorinated hydrocarbons, and most acids at moderate temperatures. The polymer, however, may be attacked by saturated steam, strong bases, and some high temperature
acid systems. The effects of a number of specific chemicals on the tensile strength of TORLON 4203L are presented in Table 11. Proper post-cure of TORLON parts is
necessary to achieve optimal chemical resistance.
Chemical
Tensile strength
% retained
Acids
Acetic (10%) . . . . . . . . . . . . . . . . . . 100
Glacial acetic . . . . . . . . . . . . . . . . . 100
Acetic anhydride . . . . . . . . . . . . . . 100
Lactic . . . . . . . . . . . . . . . . . . . . . . . . 100
Benzene sulfonic . . . . . . . . . . . . . . . 28
Chromic (10%) . . . . . . . . . . . . . . . . . 100
Formic (88%) . . . . . . . . . . . . . . . . . . . 66
Hydrochloric (10%). . . . . . . . . . . . . 100
Hydrochloric (37%). . . . . . . . . . . . . . 95
Phosphoric (35%) . . . . . . . . . . . . . . 100
Sulfuric (30%) . . . . . . . . . . . . . . . . . 100
Bases
Ammonium hydroxide (28%) . . . . . 81
Sodium hydroxide (15%) . . . . . . . . . 43
Sodium hydroxide (30%) . . . . . . . . . . 7
Aqueous solutions (10%)
Aluminum sulfate . . . . . . . . . . . . . . 100
Ammonium chloride . . . . . . . . . . . 100
Ammonium nitrate . . . . . . . . . . . . . . 98
Barium chloride . . . . . . . . . . . . . . . 100
Bromine (saturated solution, 120°F) 100
Calcium chloride . . . . . . . . . . . . . . 100
Calcium nitrate . . . . . . . . . . . . . . . . . 96
Ferric chloride . . . . . . . . . . . . . . . . . 99
Magnesium chloride . . . . . . . . . . . 100
Potassium permanganate . . . . . . 100
Sodium bicarbonate . . . . . . . . . . . 100
Silver chloride . . . . . . . . . . . . . . . . 100
Sodium carbonate . . . . . . . . . . . . . 100
Sodium chloride . . . . . . . . . . . . . . . 100
Sodium chromate . . . . . . . . . . . . . 100
Sodium hypochlorite . . . . . . . . . . . 100
Sodium sulfate . . . . . . . . . . . . . . . . 100
Sodium sulfide . . . . . . . . . . . . . . . . 100
Sodium Sulfite . . . . . . . . . . . . . . . . 100
Alcohols
2-Aminoethanol . . . . . . . . . . . . . . . . . 9
n-amyl alcohol . . . . . . . . . . . . . . . . 100
n-butyl alcohol . . . . . . . . . . . . . . . . 100
Cyclohexanol. . . . . . . . . . . . . . . . . . 100
Ethylene glycol . . . . . . . . . . . . . . . . 100
Chemical
Tensile strength
% retained
Aldehydes & ketones
Acetophenone . . . . . . . . . . . . . . . . 100
Benzaldehyde . . . . . . . . . . . . . . . . 100
Cyclohexanone . . . . . . . . . . . . . . . 100
Formaldehyde (37%) . . . . . . . . . . . 100
Furfural . . . . . . . . . . . . . . . . . . . . . . . 84
Methyl ethyl ketone . . . . . . . . . . . 100
Chlorinated organics
Acetyl chloride (120°F) . . . . . . . . . 100
Benzyl chloride (120°F) . . . . . . . . . 100
Carbon tetrachloride . . . . . . . . . . . 100
Chlorobenzene . . . . . . . . . . . . . . . . 100
2-Chloroethanol . . . . . . . . . . . . . . . 100
Chloroform (120°F) . . . . . . . . . . . . . 100
Epichlorohydrin . . . . . . . . . . . . . . . 100
Ethylene chloride . . . . . . . . . . . . . . 100
Esters
Amyl acetate . . . . . . . . . . . . . . . . . . 100
Butyl acetate . . . . . . . . . . . . . . . . . . 100
Butyl phthalate . . . . . . . . . . . . . . . . 100
Ethyl acetate . . . . . . . . . . . . . . . . . . 100
Ethers
Butyl ether . . . . . . . . . . . . . . . . . . . 100
Cellosolve . . . . . . . . . . . . . . . . . . . . 100
P-Dioxane (120°F). . . . . . . . . . . . . . 100
Tetrahydrofuran . . . . . . . . . . . . . . . 100
Hydrocarbons
Cyclohexane . . . . . . . . . . . . . . . . . . 100
Diesel fuel . . . . . . . . . . . . . . . . . . . . . 99
Gasoline (120°F) . . . . . . . . . . . . . . . 100
Heptane . . . . . . . . . . . . . . . . . . . . . . 100
Mineral oil . . . . . . . . . . . . . . . . . . . . 100
Motor oil . . . . . . . . . . . . . . . . . . . . . 100
Stoddard solvent . . . . . . . . . . . . . . 100
Toluene. . . . . . . . . . . . . . . . . . . . . . . 100
Nitriles
Acetonitrile . . . . . . . . . . . . . . . . . . . 100
Benzonitrile . . . . . . . . . . . . . . . . . . 100
Nitro compounds
Nitrobenzene. . . . . . . . . . . . . . . . . . 100
Nitromethane . . . . . . . . . . . . . . . . . 100
Amines
Miscellaneous
Aniline . . . . . . . . . . . . . . . . . . . . . . . . 97
n-Butyl amine . . . . . . . . . . . . . . . . . 100
Dimethylaniline . . . . . . . . . . . . . . . 100
Ethylene diamine . . . . . . . . . . . . . . . . 7
Morpholine . . . . . . . . . . . . . . . . . . . 100
Pyridine . . . . . . . . . . . . . . . . . . . . . . . 43
Cresyldiphenyl phosphate . . . . . . 100
Sulfolane . . . . . . . . . . . . . . . . . . . . . 100
Triphenylphosphite. . . . . . . . . . . . . 100
TORLON parts maintain high performance in hostile
chemical environments.
– 24 –
Performance in Various Environments
Chemical Resistance Under Stress
Resistance To Automotive and Aviation Fluids
Table 13
Of particular interest to aerospace and automotive engineers is the ability of a polymer to maintain its properties
after exposure to commonly used fluids. Total immersion
tests show TORLON poly(amide-imide) is not affected by
common lubricating fluids at 300°F (149°C), aircraft hydraulic fluid at low temperatures, and turbine oil, even under stress at elevated temperatures. At 275°F (135°C), aircraft hydraulic fluid reduces strength slightly. Tables 12
and 13 summarize the methods and results of specific
fluid immersion tests.
Tensile strength retention after immersion in aircraft
4
hydraulic fluid
Tested at room temperature
Tensile strength,
Elongation,
percent of initial percent of initial
TORLON 4301
1,000 hours at 275°F (135°C)
1,000 hours at -108°F (-80°C)
TORLON 4275
1,000 hours at 275°F (135°C)
1,000 hours at -108°F (-80°C
Automotive Lubricating Fluids
Property retention after immersion in 300°F (149°C)
automotive lubricating fluid.
Tested at room temperature
TORLON 4275
Weight
Flexural
change
strength
%
retained, %
0.0
95.5
0.0
100.3
0.0
94.2
+0.2
102.7
+0.2
100.6
92.7
101.3
119.3
129.8
Aircraft Turbine Oil, With and Without Stress
Table 12
Motor oil 1
Transmission
fluid 2
Gear lube 3
94.1
95.8
4 Skydrol 500B. Skydrol is a registered trademark of Monsanto Company
ASTM D790 specimens were tested at room temperature
after immersion in 300°F (149°C) lubricating fluids for one
month. TORLON 4203L and 4275 have excellent property
retention under these conditions (Table 12).
TORLON 4203L
Weight
Flexural
change
strength
%
retained, %
0.0
99.4
89.6
94.0
TORLON parts have exceptional resistance to Aeroshell
500 turbine oil5 under stress at elevated temperatures.
Turbine oil affects TORLON 4203L and 7130 only slightly;
after 100 hours of exposure under stress, 4203L maintains
more than 80 percent of its ultimate tensile strength at
temperatures up to 400°F (204°C) without rupturing, and
7130, a graphite fiber reinforced grade, is even better, tolerating stress levels of 80 percent of ultimate at temperatures up to 450°F (232°C).
In another test, without stress, essentially no change in
the tensile strengths of TORLON 4203L and 4301 was observed after 1000 hours in Aeroshell 500 at 302°F (150°C).
5
Aeroshell is a registered trademark of Shell Oil Company
Chemical Resistance Under Stress
Aircraft Hydraulic Fluid (SKYDROL 500B)
TORLON bearing grades 4301 and 4275 were immersed in
aircraft hydraulic fluid for 41 days at -108°F (-80°C) and
275°F (135°C). Both TORLON grades were mildly affected
by the fluid at 275°F (135°C), showing a loss in tensile
strength of about 10 percent. It is noteworthy that this loss
was not a result of embrittlement as tensile elongation
was maintained. Tests show TORLON 4203L bar specimens resist cracking, softening, and breakage under high
stress in aircraft hydraulic fluid. Low temperature testing
showed no significant effect on either grade.
TORLON parts which had been thoroughly post-cured
were tested* for resistance to the following chemical environments; aviation gasoline, turbine fuel (Jet A/A-1), hydraulic fluid, methyl ethyl ketone, methylene chloride, 1,1,1
trichloroethane, and toluene. TORLON specimens resisted
breakage, cracking, swelling, and softening.
– 25 –
*
5 x 0.5 x 0.125 inch (12.7 x 1.3 x 0.318 cm) specimens were clamped over a
5.0 inch (12.7 cm) curve. The test chemical was applied to the middle of
each specimen for one minute. The application was repeated after one and
two hours. Specimens were inspected after 24 hours for breakage,
cracking, swelling, and softening.
Effects of Water
Effects of Water
Equilibrium Absorption at Constant Humidity
Like other high-temperature engineering resins and composites, TORLON parts absorb water, but the rate is slow
and parts can be rapidly restored to original dimensions
and properties by drying.
At constant humidity, a TORLON part will absorb an equilibrium amount of water. The levels for a range of relative
humidity are shown in Figure 22 using uniform panels
5 x ½ x 1 8 inch (127 x 13 x 3 mm).
Absorption Rate
Figure 22
TORLON poly(amide-imide) must be exposed to high humidity for a long time to absorb a significant amount of
water. The rate of absorption depends on polymer grade,
temperature, humidity, and part geometry.
Relative humidity determines equilibrium moisture
absorption at room temperature
5
Weight increase, %
Figures 20 and 21 report results obtained with uniform
bars 5 x ½ x 1 8 inch (127 x 13 x 3 mm). Water absorption is
dependent on diffusion into the part and is inversely proportional to part thickness.
Figure 20
Water absorption of TORLON polymers at 73°F (23°C),
50% relative humidity
3L
20
N4
LO
R
TO
301
N4
RLO
TO
030
5
N
RLO
TO
0
713
LON
TOR
4
3
2
1
0
0
Weight increase, %
10
20
30
3L
TORLON 420
2.5
2
0
LON 713
TOR
1.5
TORLON 4301
4275
TORLON
TORLON 5030
1
0.5
0
100
200
300
Time, days
400
50
60
70
80
90
100
Dimensional Changes
TORL ON 43 47
0
40
Relative humidity, %
500
Small dimensional changes occur as TORLON parts absorb water. Figures 23 and 24 show dimensional changes
of the standard test part with exposure to atmospheric
moisture at specified temperatures. As with absorption
rate, the change is greatest for TORLON 4203L, the grade
with least filler or reinforcement.
Figure 23
Dimensional changes of TORLON polymers at
73°F (23°C), 50% relative humidity
Figure 21
Water absorption of TORLON polymers at 110°F
(43°C), 90% relative humidity
Change, 0.001 in./in.
2
Weight increase, %
5
TORLON 4203L
4
TORLON 4301
3
TORLON 4275
TORLON 4347
203L
N4
RLO
O
T
1.5
347
N4
LO
R
TO
TORLON 5030
1
TORLON 4275
TORLON 4301
0.5
TORLON 7130
TORLON 5030, 7130
2
0
0
1
0
0
50
100
150
Time, days
200
250
– 26 –
100
200
300
Time, days
400
500
Effects of Water
Constraints on Sudden High Temperature Exposure
Figure 24
Absorbed water limits the rate at which TORLON parts
can be heated. Sudden exposure to high temperature can
distort or blister parts unless absorbed water is allowed to
diffuse from the part. Solvay Advanced Polymers uses the
term “thermal shock temperature” to designate the temperature at which any distortion* occurs upon sudden exposure to heat.
Dimensional change of TORLON polymers at
110°F (43°C), 90% relative humidity
Change, 0.001 in./in.
5
ON
RL
TO
4
L
03
42
ON
RL
TO
3
1
430
75
TORLON 42
347
4
ON
RL
TO
Original dimensions and properties can be restored by
drying TORLON parts. The temperature and time required
depend on part size and geometry. For the test panels in
this study, original dimensions were restored by heating
for 16 hours at 300F (149C).
Figure 25 relates thermal shock temperature to moisture
content for TORLON 4203L, the grade most sensitive to
water absorption. At 2½ percent absorbed water (which is
equilibrium at 50 percent relative humidity and room temperature) the thermal shock temperature is well over
400°F (204°C). Thermal shock is related to exposure time
in Figure 26. Even after over 200 hours at 57.8 percent relative humidity and 73°F (23°C), the test part made with
TORLON 4203L did not distort until sudden exposure to
over 400°F (204°C). Other grades of TORLON resin exhibit
lower equilibrium water absorption (refer to Figure 22) and
their thermal shock temperatures are therefore higher.
Thermal shock temperature can be restored to its highest
level by drying at 300°F (149°C) for 24 hours for each 1 8
inch (3 mm) of part thickness.
Changes in Mechanical and Electrical Properties
*
TORLON 5030
2
TORLON 7130
1
0
50
100
150
Time, days
200
250
Restoration of Dimensions and Properties
To illustrate the change in mechanical properties with water absorption, test specimens were immersed in water
until their weight increased by 2 percent. Table 14 compares the properties of these panels with those of panels
conditioned for 40 hours at 73°F (23°C) and 50 percent relative humidity A slight reduction in stiffness is the most
noticeable change
Figure 25
Thermal shock temperature versus moisture
content of TORLON 4203L
350
600
Thermal shock temperature, °F
Absorbed water reduces the electrical resistance of
TORLON resin and slightly changes dielectric properties.
With 2 percent moisture, TORLON specimens had volume
and surface resistivities of 1 x 1016 ohm/inch (3 x 1014
ohm/m) and 1 x 1017 ohm respectively, and dielectric
strength of 620 V/mil (24 kV/mm).
Table 14
Percent change in properties of
TORLON 4203L with 2% absorbed water
Property
Tensile strength
Tensile modulus
Elongation
Shear strength
lzod impact strength
Dielectric constant
Dissipation factor
Test bars 5 x ½ x 1 8 inch (127 x 13 x 3 mm) are exposed to 57.8 percent
relative humidity and 73°F (23°C) over a specified period of time, and placed
in a circulating air oven preheated to the test temperature. After one hour
the samples are visually inspected and measured. Failure occurs if blisters
or bubbles appear, or if dimensional change over 0.001 inch (25
micrometers) is measured. The temperature at which failure is evident is
the thermal shock temperature.
Percent change
-7
-11
13
1
20
18
53
300
TORLON
4203L
500
400
200
300
150
200
100
50
100
0
– 27 –
250
°C
0
0.5
2
1
1.5
Moisture level weight %
2.5
3
0
Weather-Ometer® Testing
Figure 26
Figure 28
Thermal shock temperature versus exposure time for
TORLON 4203L
Change in tensile strength of TORLON 4203L with exposure to simulated weathering
350
T O RLON
250
4203 L
400
200
300
150
200
100
35
30
150
20
15
10
100
10
50
0
80
200
40
160
120
Exposure time, days at 57.8% RH, room temperature
100
500
1,000
5,000 10,000
Exposure time, hours
50
100
200
TORLON 4 203L
25
N/mm2
500
Tensile strength, 103 psi
300
°C
Thermal shock temperature, °F
600
240
®
Weather-Ometer Testing
Resistance to Gamma Radiation
TORLON molding polymers are exceptionally resistant to
degradation by ultraviolet light. TORLON 4203L did not degrade after 6,000 hours of Weather-Ometer exposure (Figures 27 and 28) which is roughly equivalent to five years of
outdoor exposure. The bearing grades, such as 4301, contain graphite powder which renders the material black
and screens UV radiation. These grades are even more
resistant to degradation from outdoor exposure.
Figure 29 shows the negligible effect gamma radiation has
on TORLON poly(amide-imide)-only about 5 percent loss in
tensile strength after exposure to 109 rads.
Figure 29
Percent change in physical properties of TORLON
4203L after exposure to gamma radiation
50
Flexural Modulus
40
Tensile Strength
30
Change vs. Control, %
Tensile bars (ASTM D1 708) were exposed in an Atlas
Sunshine Carbon Arc Weather-Ometer. Bars were removed after various exposure periods and tensile strength
and elongation were determined. The test conditions
were a black panel temperature of 145°F (63°C), 50 percent relative humidity and an 18-minute water spray every
102 minutes.
Elongation
20
10
0
-10
-20
-30
-40
-50
Figure 27
0
Elongation, %
14
TORLON 4203L
10
8
6
50
100
500
1,000
3
10
4
10
105
6
10
107
Radiation exposure level, rads (10 rad/hr exposure rate)
16
10
102
6
The elongation of TORLON 4203L is essentially constant after exposure to simulated weathering
12
101
5,000 10,000
Exposure time, hours
– 28 –
108
109
Electrical Properties
Electrical Properties
Most TORLON grades provide electrical insulation.
TORLON poly(amide-imide) provides a unique combination
of high temperature service and ease of moldability into
complex electrical and electronic parts. Special grades of
TORLON engineering polymer are conductive. TORLON
7130, a conductive grade, effectively shields electromagnetic interference. The design engineer should consider
the significant electrical properties of a material, such as
those summarized in Table 15.
TORLON polymers for insulating
Table 15
Important electrical considerations
Property
ASTM
test
method
Dielectric constant
D150
The ratio of the capacity of a
condenser filled with the material
to the capacity of an evacuated
capacitor. It is a measure of the
ability of the molecules to become
polarized in an electric field. A low
dielectric constant indicates low
polarizability; thus the material
can function as an insulator.
Dissipation factor
DI50
A measure of the dielectric loss
(energy dissipated) of alternating
current to heat. A low dissipation
factor indicates low dielectric
loss, while a high dissipation
factor indicates high loss of
power to the material, which may
become hot in use at high
frequencies.
Volume resistivity
Surface resistivity
Dielectric strength
D257
D257
D149
Significance
TORLON engineering polymers demonstrate excellent
electrical properties and maintain them in a variety of environments. The dielectric strength of the grades shown in
Table 16 are high indicating these grades provide outstanding electrical insulation. Also indicative of the
insulative capability of TORLON resins are the high values
shown for volume resistivity.
Table 16
Electrical properties of TORLON resins
TORLON Grade
The electrical resistance of a unit
cube calculated by multiplying the
resistance in ohms between the
faces of the cube by the area of
the faces. The higher the volume
resistivity, the better the material
will function as an insulator.
The resistance to electric current
along the surface of a one square
centimeter sample of material.
Higher surface resistivity
indicates better insulating
properties.
A measure of the voltage an
insulating material can take
before failure (dielectric
breakdown). A high dielectric
strength indicates the material is
a good insulator.
4203L
4301*
4275*
4347*
5030
Volume resistivity
(ASTM D257)
ohm•in
ohm•m
8 x 1016
2 x 1015
3 x 1015
8 x 1013
3 x 1015
8 x 1013
3 x 1015
8 x 1013
6 x 1016
2 x 1015
Surface resistivity
(ASTM D257)
ohm
5 x 1018
8 x 1017
4 x 1017
1 X 1018
1 X 1018
Dielectric strength,
0.040 in
(ASTM D 149)
V/mil
kV/mm
580
24
Dielectric constant
(ASTM D150)
103 Hz
106 Hz
4.2
3.9
6.0
5.4
7.3
6.6
6.8
6.0
4.4
6.5
Dissipation factor
(ASTM D150)
103 Hz
106 Hz
0.026
0.031
0.037
0.042
0.059
0.063
0.037
0.071
0.022
0.023
840
33
*Contains graphite powder. By these tests, they behave as insulators, but they
may behave in a more conductive manner at high voltage or high
frequency.
– 29 –
Conductivity and EMI Shielding
Table 17
TORLON grade
Method
7130
Volume resistivity
D257
ohm•in
3 x 106*
ohm•m
8 x 104*
Surface resistivity
D257
5 X 107*
ohm
*
Molded specimen—plaque 3.0 x 4.5 x 0.190 inch (7.6 x 11.4 x 0.48 cm)
Table 18
Attenuation in decibels and shielding effectiveness
EMI from electronic devices is under the Jurisdiction of
the Federal Communications Commission (FCC) in the U.S.
The VDE in West Germany and similar agencies around
the world have taken steps to control this serious problem. The frequency of EMI ranges from 1 MHz to 1,000
MHz. Regulations limiting EMI make it necessary for design engineers to select a material that can attenuate
EMI.
Two techniques, dual chamber and transmission line, are
used to determine decibel attenuation (reduction) provided by a material. Attenuation is related logarithmically
to shielding effectiveness and is measured by detecting
the EMI penetrating a test specimen. The dual chamber
method is used to gauge EM I in the “near field.” This
would relate to the ability of a material to shield EMI emanating from devices operating in relatively close proximity.
Transmission line data is more relevant in analysis of “far
field” effects, such as noise in space emanating from
earth or vice versa.
ASTM
Attenuation,
dB
Shielding
effectiveness, %
Description
0 – 10
0 – 90
Ineffective.
10 – 30
90 – 99.9
Minor amounts of EMI
eliminated.
30 – 60
99.9 – 99.9999
Moderate amounts of EMI
eliminated. Considered adequate
for the large majority of current
applications.
60 – 90
99.9999 – 99.9999999
Moderate to severe EMI
eliminated.
90 – 120
99.9999999 –
99.9999999999
Maximum possible reduction.
Over 120
99.9999999999 +
Considered unattainable.
Figure 30
Near field EMI shielding effectiveness,
dual chamber method
Shielding effectiveness is expressed as a percent. Table
18 shows the correlation between shielding effectiveness
and decibel attenuation. A material rated at 30dB attenuation would prevent 99.9 percent of the electromagnetic radiation from penetrating through it.
TORLON 7130 was tested for far field and near field shielding effectiveness and was shown to have potential for
shielding in both categories. Figures 30 and 31 relate the
results of this testing.
0
0
90
10
99
99.9
30
99.99
40
99.999
50
99.9999
60
100
– 30 –
20
TORLON 7130
200
300
400 500 600
Frequency, MHz
700
800
900 1,000
Decibel attenuation
TORLON 7130, a graphite fiber reinforced grade is sufficiently conductive to shield electromagnetic interference
(EMI). EMI emanates from both natural and man-made
sources. Tremendous growth in electrical devices, such
as personal computers, pocket pagers, CB radios, and
telephones, has contributed to a dramatic increase in EMI
“noise” Such devices create and are affected by EMI.
EMI noise makes garage doors open and computers shut
down; it interferes with communications, and navigational
systems.
Electrical resistance properties of TORLON 7130
Shielding effectiveness, %
Normally, TORLON poly(amide-imide) has superior insulating qualities, however, addition of graphite fiber produces
a resin with electrical conductivity Table 17 shows the low
volume resistivity and surface resistivity of the conductive
TORLON grades. ASTM D257 is an excellent test for measuring the resistivity of insulators, but reproducibility is
unsatisfactory when dealing with conductors. This data
should not be considered absolute, but as a guideline for
distinguishing materials that insulate from materials that
conduct electrically
Figure 31
0
0
90
10
TOR
LON
7130
99
20
99.9
30
99.99
40
99.999
50
99.9999
60
100
200
300
400 500 600 700
Frequency, MHz
800
Decibel attenuation
Shielding effectiveness, %
Far field EMI shielding effectiveness,
transmission line method
900 1,000
TORLON spline liners are tough, wear resistant and useful
through a wide temperature range. The TORLON part does not
gall, resists fretting and requires no lubrication.
– 31 –
Service Under Conditions of
Friction and Wear
Figure 32
Material wear rate is a function of the Pressure-Velocity (PV) product
New possibilities in the design of moving parts are
opened by TORLON wear resistant grades; 4301, 4275, and
4347. These grades offer high compressive strength and
modulus, excellent creep resistance, and outstanding retention of strength and modulus at elevated temperatures,
as well as self-lubricity and low coefficients of thermal
expansion, which make them prime candidates for wear
surfaces in severe service. TORLON bearings are dependable in lubricated, unlubricated, and marginally lubricated
service. Some typical applications which lend themselves
to this unique set of properties are ball bearings, thrust
washers, piston rings, vanes, valve seats, bushings and
wear pads.
Wear Rate Defined as PV Service Limits
The service regime of bearings is often defined as the
pressure-velocity product (PV) limit. A given material will
have a characteristic PV limit. Below the PV limit, wear is
moderate; above the PV limit, wear is rapid as demonstrated in Figure 32. Due to heat of friction, bearings in
service above the PV limit of the material wear very rapidly and may actually melt.
Wear factor, K
PV
Limit
PV
TORLON polymers have wear factors similar to those of
more expensive polyimide resins, and there is a distinct
cost advantage in choosing TORLON poly(amide-imide). In
addition, TORLON resins are injection moldable polyimides are not.
Unlubricated Wear Resistance
Evaluation by Thrust Washer Friction and Wear Method
Wear data has been developed using tests run on an
unlubricated thrust washer. This procedure has been
found to be more reproducible than tests using journal
bearings and the results can predict journal bearing test
results with a fair degree of confidence. Table 19 shows
wear factor (K), and coefficient of friction data for
TORLON wear resistant grades at 10,000, 45,000, and
50,000 PV. All three wear resistant grades are useful in excess of 50,000 PV. Most other engineering resins fail far
below this level.
Whenever two solids rub against each other, some wear
is inevitable. The rate at which wear occurs is related to
pressure and velocity by the following empirical equation:
t = KPVT
where:
t = wear, inches
K = wear factor determined at a given P and V, in
units of in3min/ft lb hr
P = pressure on bearing surface, psi
V = bearing surface velocity, ft/min
T = time, hours
Low wear factors (K) are characteristic of wear resistant
materials. Fluorocarbons, which have low coefficients of
friction, have very low wear factors, but limited mechanical properties and poor creep resistance. At low PV’s,
TORLON wear resistant grades have wear factors comparable to filled polytetrafluoroethylene (pTFE), a fluorocarbon, but TORLON polymers offer superior creep resistance and strength.
Figure 33 compares TORLON wear resistant grades to two
engineering resins commonly used for wear surfaces. Under the test conditions*, TORLON wear resistant grades
are similar in wear rate to the more expensive polyimide
Vespel** SP21. At low PVs, TORLON wear rates are similar to filled pTFE (**Vespel is a registered trademark of E.I.
DuPont de Nemours and Company).
– 32 –
Service Under Conditions of Friction and Wear
Effect of Mating Surface on Wear Rate
Figure 34
Thrust Washer Friction and Wear Test Method
Thurst washer test specimen
The Faville-LeValley FALEX 6 Thrust Washer Test Machine
is used to evaluate the friction and wear properties of resins using a small rotating test specimen (Figure 34). A stationary washer machined from C1018 steel having a
surface roughness of 12.0 ± 0.50 µ inch root-mean square
is the reference material, although other materials and tolerances can be used. Following the manufacturer’s instructions, calculate the speed and load from accurate
measurement of the rotating test specimen for the desired
velocity and pressure. Several measurements should be
made to assure uniformity of the specimen.
Initiate the test following the manufacturer’s instructions
and obtain the static coefficient of friction. Allow the test
to proceed for at least 40 hours or until the specimen
wears down 10 mils, whichever requires the longer
elapsed time. If the specimen wears quickly, terminate the
test after 50 mils of wear, as approximated by wear gauge
readings. After kinetic temperature equilibrium is reached,
several torque readings should be obtained and averaged
to obtain the kinetic coefficient of friction. Because static
coefficients are determined at room temperature and kinetic coefficients at equilibrium temperature, this procedure yields static coefficients which are lower than kinetic
coefficients. The wear factor is calculated from the difference between initial and final thickness measurements
taken in equilibrium at room temperature and the pressure
and velocity used.
.185
.180
.078 Dia.
.095
.085
.0005
D.
1.125
1.120
D.
1.005
1.000
.250 D.
.255
±.003
.437
All dimensions are in inches
Effect of Mating Surface on Wear Rate
The wear data presented in Table 19 and Figure 33 were
determined using C1018 steel hardened to 24 on the
Rockwell C scale. Other metals were tested against
TORLON 4301 to evaluate the role of the mating surface.
The results are shown in Table 20.
Figure 33
Wear resistance of TORLON resins compares to that of polyimide
50
PV = 10,000
PV = 10,050
VP =
200
Wear factor, 10-10K
40
PV = 50000
PV = 01000
VP =
50
PV = 45000
PV = 10050
VP = 900
30
20
10
0
TORLON
4301
TORLON
4275
TORLON
4347
Vespel
SP21
Carbonfilled
pTFE
TORLON
4301
TORLON
4275
– 33 –
TORLON
4347
Vespel
SP21
TORLON
4301
TORLON
4275
TORLON
4347
Vespel
SP21
Table 19
Wear characteristics of TORLON bearing grades using hardened C1018 steel as a reference
TORLON grade
Wear characteristics*
4301
Wear factor K (10-10in3•min/ft•lb•hr)
PV= 10,000
17
PV = 45,000
53
PV = 50,000
41
Coefficient of friction, static
PV= 10,000
0.06
PV = 45,000
0.13
PV = 50,000
0.11
Coefficient of friction, kinetic’
PV= 10,000
0.27
PV = 45,000
0.14
PV = 50,000
0.12
*Pressure and Velocity for PV values
PV
10,000
Pressure, psi
50
Velocity, fpm
200
4275
4347
8
40
31
6
42
24
0.02
0.07
0.14
0.02
0.08
0.08
0.19
0.15
0.11
0.19
0.13
0.11
45,000
50
900
50,000
1,000
50
Table 20
Wear characteristics of TORLON 4301 against various metals
Metal used as mating surface for TORLON 4301
C1018
(Standard)
C1018
Soft
316
Stainless
steel
Brass (free
cutting)
Aluminum die
casting alloys
A360
A380
24
6
17
-15
-24
-28
K relative to standard at PV= 45,000
1.0
1.4
7.5
2.1
1.3
1.2
K relative to standard at PV= 50,000
1.0
1.2
1.2
1.5
1.5
0.9
PV=45,000
0.12
0.15
0.13
0.11
0.11
0.10
PV = 50,000
0.11
0.08
0.07
0.04
0.05
0.04
PV = 45,000
0.14
0.17
0.20
0.26
0.20
0.18
PV = 50,000
0.13
0.13
0.12
0.23
0.13
0.13
PV
45,000
50,000
Pressure, psi
50
1,000
Velocity, fpm
900
50
Rockwell hardness, C scale
Wear factor,* K (10-10in3•min/ft•lb•hr)
Coefficient of friction, kinetic
*Pressure and velocity for PV values
– 34 –
Service Under Conditions of Friction and Wear
Lubricated Wear Resistance
Lubricated Wear Resistance
Figure 35
PV (P/V = 50/900)
45,000
Wear factor, K
(10-10 in3•min/ft•lb•hr)
1.0
0.08
Coefficient of friction, kinetic
0.10
Wear depth at 1,000 hours, in (mm)
0.0045 (0.11 mm)
500
500
450
400
300
200
400
350
an
ce
100
0
2
4
6
8
Cure temperature, °F
Lubricated wear resistance of TORLON 4301
Cure cycle
K, 10-10 in3 min / ft lb hr
Wear factor, K x 10-10
Table 21
Extended cure at 500°F (260°C) improves wear resistance (cure cycles are a function of part geometry)
t
is
res
ear
1W
430
ON
RL
TO
The impressive performance of TORLON bearing grades in
nonlubricated environments is insurance against catastrophic part failure or seizure upon lube loss in a normally lubricated environment. In a transmission lubricated
with hydrocarbon fluid, TORLON thrust washers are performing well at PVs of 1,300,000. In a water lubricated hydraulic motor vane, excellent performance has been attained at over 2,000,000 PV. Table 21 summarizes the wear
characteristics of TORLON 4301 immersed in hydraulic
fluid.
300
10
12
250
Cure cycle, days
Cure cycle consisted of one day at each of the following temperatures: 300°F
420°F, 470°F followed by post-cure at 500°F as indicated in Figure 35 (149,
216, 243, and 260°C respectively).
Wear Resistance and Post-Cure
The wear resistance of TORLON parts depends on proper
post-cure. A thorough and complete post-cure is necessary to achieve maximum wear resistance. To illustrate
the dependence of wear resistance on post-cure, a sample of TORLON 4301 was post-cured through a specified
cycle* and tested for wear resistance at various points in
time. The results of that test and the cure cycle are shown
in Figure 35. In this case, the Wear Factor, K, reached a
minimum after eleven days, indicating achievement of
maximum wear resistance.
The length of post-cure will depend on part configuration,
thickness, and to some extent on conditions of molding.
Very long exposure to 500°F (260°C) is not detrimental to
TORLON parts. The suitability of shorter cycles must be
verified experimentally.
– 35 –
Industry and Agency Approvals
Industry and Agency Approvals
National Aeronautics and Space Administration
NHB8060.1 “Flammability, Odor, and Offgassing
Requirements and Test Procedures for Materials in
Environments that Support Combustion” TORLON
4203L and 4301 have passed the NASA spacecraft
materials requirements for non-vacuum exposures per
NHB8060.1.
TORLON engineering polymers have been tested successfully against many industry standards and specifications.
The following list is a summary of approvals to date, but
should not be considered inclusive, as work continues to
qualify TORLON poly(amide-imide) for a myriad of
applications.
Society of Automotive Engineers-Aerospace
Material Specifications
Underwriters Laboratories
Vertical Flammability
All TORLON grades have been awarded a 94 V-0
classification. See Table 10 on page 23.
AMS 3670 is the specification for TORLON N materials.
The specification suggests applications requiring a
low coefficient of friction, thermal stability, and
toughness up to 482°F (250°C). TORLON 4203L, 4275,
4301, 5030, and 7130 are covered in the detail
specifications:
AMS 3670/1-TORLON 4203L
AMS 3670/2-TORLON 4275
Continuous Use
The Thermal Indices of TORLON 4203L, 4301, and 5030
are shown in Table 5 on page 18.
Federal Aviation Administration
TORLON 5030 and 7130 pass FAA requirements for
flammability, smoke density, and toxic gas emissions.
Military Specifications
MIL-P-46179A Plastic Molding and Extrusion materials,
Polyamide-imide This specification covers
poly(amide-imide) thermoplastic materials intended for
use up to 500°F (260°C), classified as follows
Type I
general purpose
TORLON 4203L
Type 11 bearing applications
Class 1
Class 2
Class 3
TORLON 4301
TORLON 4275
TORLON 4347
Type III glass fiber reinforced
Class 1
Class 2
TORLON 5030
TORLON 9040
Type IV 30% carbon fiber reinforced
TORLON 7130
– 36 –
Material Efficiency—Specific Strength and Modulus
Structural Design
Material Efficiency—Specific
Strength and Modulus
Reducing weight can be the key to lower cost, reduced
friction, and decreased energy consumption. When
TORLON engineering polymer replaces metal, the
TORLON part can support an equivalent load at significantly lower weight.
The ratio of a material’s tensile strength to its density
(specific strength) provides information about “material
efficiency” The specific strength of TORLON 5030, for example, is 530,000 inches (13,500 m), compared with 379,000
inches (9,600 m) for stainless steel. Therefore, a TORLON
5030 part will weigh almost 40% less than a stainless steel
part of equivalent strength. Similarly, the specific modulus
of a material is of interest when stiffness of the part is
crucial to performance. Comparison of material efficiency
data* in Table 22 shows that TORLON parts can beat the
weight of most metal parts.
Table 22
Specific strength and modulus of TORLON polymers
and selected metals
TORLON 4203L
TORLON 5030
TORLON 7130
Aluminum alloys, heat
treated
2011
2054
7075
Titanium 6-2-4-2
Stainless steel, 301
*
Specific strength
103 m
103 in
556
14.1
530
13.5
576
14.6
539
700
821
793
379
13.7
17.8
20.8
20.1
9.6
Specific stiffness
106 in
105 m
14.6
3.7
30.3
7.7
56.5
14.4
100.0
106.0
103.0
100.6
96.5
25.4
26.9
26.1
25.5
24.5
Strength and stiffness of metals were calculated from physical properties
as tabulated in the 1984 Materials Selector issue of Materials Engineering,
December, 1983.
– 37 –
Examples of Stress and Deflection Formula Application
Structural Design
Geometry and Load Considerations
Example 1–Short-term loading
The maximum bending stress, Smax, occurs at
In the early stages of part design, standard stress and deflection formulas should be applied to ensure that maximum working stresses do not exceed recommended
limits.
L/2 and M =
S max =
Examples of Stress and Deflection Formula
Application
Recommended maximum working stresses for TORLON
engineering polymers appear in Table 23. To illustrate how
these values may be used, the maximum load for a beam
made of TORLON 5030 will be calculated under various
loading conditions at room temperature. Figure 36 shows
the beam dimensions and the calculation of the moment
of inertia (I).
WL
.
4
WLc
4I
Solving for W and substituting the recommended maximum working stress for TORLON 5030 under a short-term
load at room temperature:
Wmax =
4S max I (4)(17800 psi)(0.0026 in 4)
= 247 lb
=
Lc
(3.0 in.)(0.25 in.)
Figure 36
Therefore, the maximum short-term load for a TORLON
5030 beam at room temperature is approximately 247
pounds.
Beam used in examples
The maximum deflection for this beam is:
Y max =
W
d = 0.50
L = 3.0
WL3 L
at
48EI 2
Where E is the flexural modulus of TORLON 5030 obtained
from the Properties Table.
Y max =
b = 0.25
(247 lb)(3.0 in) 3
= 0.034 in
(48)(15.6 ´ 10 5 psi)(0.0026 in 4)
Therefore, the predicted maximum deflection is 0.034 in.
W = Load, lb
L = Length of beam between supports, in
c = Distance from the outermost point in tension
to the neutral axis, in
b = Beam width, in
d = Beam height, in
I = Moment of inertia, in4
In this example:
Example 2-Steady load
In this example, the load is long-term. Creep is considered
to be the limiting factor. The maximum load which may be
applied to the TORLON 5030 beam is:
L = 3.0 in
c = 0.25 in
b = 0.25 in
d = 0.50 in
bd3 (0.25 in.) (0.50 in.) 3
I=
=
= 0.0026 in 4
12
12
M = Load x distance to support, in•lb
Wmax =
4S max I (4)(17000)(0.0026)
=
= 236 lb.
Lc
(3.0)(0.25)
To calculate the maximum deflection of the beam under a
steady load, the apparent (creep) modulus (Ea) is used
rather than the flexural modulus. Because material properties are time dependent, a finite period is selected. In
this example, maximum deflection after 100 hours is
calculated.
The apparent modulus at 100 hours can be estimated by
dividing the steady load recommended maximum working
stress from Table 23 by the assumed maximum strain (1.5
percent).
– 38 –
Geometry and Load Considerations
Ea =
Stress Concentration
17000 psi
= 1.13 ´ 10 6 psi
0.015
Circular perforations give rise to stress concentrations,
but as Figure 37 demonstrates, TORLON poly(amide-imide)
is less sensitive than metal.
Substituting:
Y max =
WL3
(236)(3.0) 3
=
= 0.045 in.
48E aI (48)(1.13 ´ 10 6 )(0.0026)
Figure 37
Stress concentration factor for circular stress raiser
(elastic stress, axial tension)
Maximum deflection at L/2 is predicted to be 0.045 inch.
3
Example 3-Cyclic load
Wmax
4S I (4)(4550)(0.0026)
= max =
= 63 lb
Lc
(3.0)(0.25)
Stress Concentration Factor, k
2.5
When materials are stressed cyclically, failures will occur
at stress levels lower than the material’s ultimate strength
due to fatigue. To calculate the maximum cyclic load our
beam can handle for a minimum of 10,000,000 cycles:
Predicted k for metal
2
1.5
TORLON 7130
TORLON 5030
1
TORLON 4203L
0.5
D
P
d
P
0
0
Stress Concentration
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
d/D
Part discontinuities, such as sharp corners and radii, introduce stress concentrations that may result in failure
below the recommended maximum working stress. It is,
therefore, critical that a part be designed so that the
stress field is as evenly distributed as possible.
– 39 –
Recommended Maximum Working Stresses for TORLON Resins
Recommended Maximum Working Stresses for
TORLON Resins
End use conditions restrict the allowable working
stresses for a structural member. Prototype evaluation is
the best method of determining the suitability of TORLON
parts. The data summarized in Table 23 are useful early in
the design process for use in the engineering equations
for the proposed part.
Table 23
Recommended maximum working stresses for injection molded TORLON resins
English units (psi)
TORLON grade
Temp. °F
Short term load
4203L
4301
4275
4347
5030
7130
73
17,000
14,000
13,000
10,700
17,800
17,600
275
10,000
9,800
9,800
9,100
13,900
13,700
450
5,700
6,400
4,900
4,700
9,800
9,400
Steady load (creep),
73
7,000
10,000
9,500
7,700
17,000
17,000
<1.5% strain, 100 hrs.
200
6,500
7,500
7,900
6,400
15,000
15,000
400
5,000
6,000
6,000
6,000
10,000
10,000
Cyclic load,
73
3,850
3,000
2,800
2,250
4,550
5,250
107 cycles
275
2,450
2,100
2,100
1,900
3,500
4,200
450
1,400
1,350
1,050
1,000
2,450
2,800
23
117
96
89
74
122
121
135
69
67
67
63
96
94
232
39
44
34
32
67
55
Steady load (creep),
23
48
69
65
53
117
117
<1.5% strain, 100 hrs.
93
45
52
54
44
103
103
204
34
41
41
41
69
69
Cyclic load,
23
26
21
19
15
31
36
107 cycles
135
17
14
14
13
24
29
232
10
9
7
7
17
19
Sl units (MPa)
Short term load
Temp. °C
– 40 –
®
Designing with TORLON Resin
Fabrication Options
TORLON poly(amide-imide) can be molded using any of
three conventional molding techniques; injection, compression and extrusion. Each has advantages and
limitations.
Injection Molding
TORLON parts can be injection molded to fine detail. Of
the three methods, injection molding produces parts of
the highest strength. When a large quantity of complex
parts is required, injection molding can be the most economical technique due to short cycle times and excellent
replication. Part thickness is limited by the flow length
versus thickness relationship of the polymer. Thickness is
limited to a maximum of 5 8 inch (15.9 mm).
Extrusion
TORLON polymers can be extruded into profiles and
shapes such as rods, tubing, sheet, film and plates. Small
parts with simple geometries can be economically produced by combining extrusion molding and automatic
screw machining. TORLON 4203L and 4301 are available
as rod stock from 1 8 to 2 inches diameter (3.2 to 50.8 mm);
and plates from 3 16 to 1 inch thick (4.8 to 25.4 mm).
Compression Molding
Large parts over -5 8 inch (15.9 mm) thick must be compression-molded. Tooling costs are considerably lower
compared with other molding techniques. Compression-molded parts will generally be lower in strength than
comparable injection-molded or extruded parts. Compression molded rod in diameters up to 15 inches (381 mm).
OD/ID tube combinations are available in sizes up to 36
inches (914 mm) outside diameter. All sizes are available
in 6 inch (152.4 mm) lengths. Compression molded plates
are available up to 3 inches (76.2 mm) thick.
– 39 –
Designing with TORLON® Resin
Wall Section
Post-curing TORLON Parts
Figure 38
TORLON parts must be post-cured. Optimal properties, especially chemical and wear resistance, are only achieved
with thorough post-cure. Best results are obtained when
TORLON parts are cured through a cycle of increasing
temperature. Cure cycle parameters are a function of the
size and geometry of a particular part.
Gradual blending between different wall thicknesses
Smooth taper
Material flow
Guidelines for Designing TORLON
Parts
Draft Angle
TORLON poly(amide-imide) can be precision molded to
fine detail using a wide range of fabricating options. Not
only can the designer select a material with outstanding
performance, but one which gives him a great deal of
design freedom.
½° to 1° draft should be allowed to facilitate removal of the
part from the mold. With TORLON resin, draft angles as low
as 1 8° have been used, but such low angles require individual analysis. Draft angle is also dependent on the depth of
draw; the greater the depth of draw, the greater the required
draft angle (see Figure 39). Part complexity will also affect
draft requirements, as will the texture of the finish. Textured
finish generally requires 1° per side for every 0.001 inch
(0.025 mm) of texture depth.
In the following sections are guidelines for designing
parts with TORLON poly(amide-imide).
Wall Section
Whenever feasible, wall thickness should be minimized
within the bounds prescribed by the end-use, to shorten
cycle time and economize on material. When sections
must be molded to thicknesses in excess of ½ inch
(12.7 mm), parts may incorporate core and rib structures,
or special TORLON grades may be used.
Figure 39
Draft
Dimensional Change Due to Draft
For small parts molded with TORLON resin, wall sections
generally range from 0.03-0.50 inch (0.76- mm), but thicknesses up to 5 8 inch (19.0 mm) are possible with reinforced or bearing grades.
TORLON poly(amide-imide) has a relatively high melt viscosity, which limits flow length for a given wall thickness.
Use of hydraulic accumulators and precise process control reduce the impact of this limitation. Many factors,
such as part geometry, flow direction, and severity of flow
path changes make it difficult to characterize the relationship between flow length and wall thickness for sections
less than 0.050 inch (1.3 mm) thick. We suggest you contact your Solvay Advanced Polymers Technical Representative to discuss the part under consideration.
Depth of Draw
Wall Transition
Where it is necessary to vary wall thickness, gradual transition is recommended to eliminate distortion and reduce
internal stresses. Figure 38 shows the desired method of
transition -- a smooth taper. It is better that the material
flows from thick to thin sections to avoid molding problems such as sinks and voids, and to minimize internal
stress.
– 40 –
Draft Angle
Guidelines for Designing TORLON Parts
Cores
Cores
Bosses
Coring is an effective way to reduce wall thickness in
heavy sections. To minimize mold cost, core removal
should be parallel to the movement of the platens.
Bosses are commonly used to facilitate alignment during
assembly, but may serve other functions. In general, the
outer diameter of a boss should be equal to or greater
than twice the inside diameter of the hole, and the wall
thickness of the boss should be less than or equal to the
adjacent wall thickness.
Draft should be added to core design. Blind cores should
be avoided, but if necessary, the general guidelines are:
for cores less than 3 16 inch (4.8 mm) diameter, the length
should be no greater than twice the diameter; if greater
than 3 16 inch (4.8 mm), length should not exceed three
times the diameter (Figure 40). For cored-through holes,
length should not exceed six times the diameter for diameters over 3 16 inch (4.8 mm), and four times the diameter
for diameters less than 3 16 inch (4.8 mm).
Undercuts
It is not possible to mold undercuts in TORLON parts unless side pulls are used. To minimize mold costs, undercuts should be avoided. If it is necessary, external undercuts can be accommodated by use of a side pull, but
internal undercuts require collapsing or removable cores.
Figure 40
Molded-in inserts
Coring recommendations for TORLON parts.
Threads molded into TORLON parts have good pull-out
strength, but if greater strength is needed, metal inserts
can be molded-in. TORLON resins have low coefficients of
thermal expansion, making them excellent materials for
applications integrating plastic and metal. For ease of
molding, inserts should be situated perpendicular to the
parting line, and should be supported so they are not displaced during injection of the molten plastic. Inserts
should be preheated to the temperature of the mold.
L
D
D T
Core diameter
< 3/16”
> 3/16”
Blind core, L
< 2D
< 3D
Cored-through
< 4D
< 6D
Table 24 defines the ratio of wall thickness around the insert to the outer diameter of the insert for common insert
materials. Sufficient material around the insert is necessary for strength.
Ribs
Ribs can increase the strength of TORLON parts without
increasing section thickness. Figure 41 shows the recommended rib size related to wall thickness. The width of the
base of the rib should equal the thickness of the adjacent
wall to avoid backfill. A taper should be used.
Table 24
Wall thickness/insert o.d. relationship
Insert material
Steel
Brass
Aluminum
Ratio of wall thickness to insert o.d.
1.2
1.1
1.0
Figure 41
Recommended rib sizes for TORLON parts.
Threads
W
½° to 1½° draft
W
Threads can be molded-in. Both internal and external
threads can be molded using normal molding practices to
Class 2 tolerance using TORLON resins. Class 3 can be
molded using very high precision tooling. In general, it is
more economical to machine threads for short runs.
Table 27 on page 44 shows the screw holding strength of
TORLON threads.
– 41 –
Designing with TORLON® Resin
Holes
Holes
Holes can serve a variety of functions. Electrical connectors, for example, have numerous small holes in close
proximity Associated with each hole is a weld line which
potentially is a weak point. The degree of weakness is related to flow distance, part geometry, and the thickness of
the wall surrounding the hole. Because TORLON resins
can be molded to close tolerances, and can be molded to
thin cross sections without cracking, they are excellent
materials for this type of part; however, each application
must be considered on an individual basis due to the complexity of design variables.
– 42 –
Secondary Operations
Joining
TORLON parts can be joined mechanically, or with
adhesives.
Table 25 gives the tensile strength of HeliCoil inserts in
TORLON 4203L and 5030. It is the axial force required to
pull the insert out of TORLON specimens at least 0.020
inch (0.51 mm).
Mechanical Joining Techniques
Molded-in Threads
The dimensional stability and creep resistance of TORLON
poly(amide-imide) allows it to be readily joined with metal
components even in rotating or sliding assemblies.
Both external and internal threads can be molded with
TORLON polymer to a Class 2 tolerance. Mating parts with
metal fasteners in TORLON threads works well because
the thermal expansion of TORLON poly(amide-imide) is
close to that of metal, therefore, there will be relatively
low thermal stress at the metal to plastic interface. Due to
the increase in mold cost, it is generally advisable to machine threads for short runs.
Snap-fit: Economical and Simple
Snap-f it is an economical and simple method of joining
TORLON parts. Although the strain limit must be considered for a snap-f it assembly which will be repeatedly assembled and disassembled, TORLON engineering polymers are excellent for this type of use, due to the superior
fatigue strength of poly(amide-imide). The high modulus,
elongation, and low creep of TORLON resins also make
them well suited for snap-f it designs. Snap-in fingers in
the locked position should be strain-free, or under a level
of stress which can be tolerated by the material. TORLON
resins can tolerate up to 10% strain for the unfilled
grades, and 5% strain for filled grades. Graphite fiber reinforced grades are not suitable for snap-fit assembly Figure 42 explains the calculation of strain for a
straight-sided finger.
Table 25
Strength of HeliCoil inserts
Threaded Fasteners
Tensile strength
Self-tapping Screws
Thread size
Engagement, in
(mm)
TORLON 4203L
lb-f
J/m
TORLON 5030
lb-f
J/m
In general, TORLON poly(amide-imide) is too tough for
self-tapping screws. Tapped holes are recommended.
Molded-in Inserts
Metal inserts can be molded into TORLON parts. Preheating the insert to the temperature of the mold is required for best results. While poly(amide-imide) has low
shrink, it is still important to have sufficient material
around the insert to distribute the stress induced by
shrinkage.
#4-40
0.224
5.7
#6-32
0.276
7.0
#8-32
0.328
8.3
#10-32
0.380
9.6
¼"-20
0.500
12.7
870
3,870
1,470
6,540
1,840
8,180
2,200
9,790
2,830
12,600
970
4,310
1,700
7,560
2,140
9,520
2,940
13,100
5,200
23,100
Threaded Mechanical Inserts
Self-threading, self-locking inserts provide a high
strength, low stress option for joining TORLON parts.
These metal inserts have an exterior “locking” feature for
anchorage in the TORLON part and allow for repeated assembly and disassembly through the threaded interior.
HeliCoil® inserts from HeliCoil Products, division of Mite
Corporation, and SpeedSerts® inserts from Tridair Fasteners, Rexnord, Incorporated, are examples of this type
of insert.
– 43 –
Bonding with Adhesives
Strength of TORLON Bolts
Table 26
Threaded fasteners molded from TORLON engineering
polymers are dependable due to the high strength, modulus, and load bearing characteristics of TORLON engineering polymers. Bolts were injection molded from
TORLON 4203L and 5030 then tested* for tensile le
strength, elongation, and torque limit (Table 26). The bolts
were 0.25 inch (0.635 cm) diameter, type 28TPI with class
2A threads.
Strength of TORLON bolts
Tensile strength
TORLON 4203L
TORLON 5030
*
Screw Holding Strength
Metal screws can securely join threaded TORLON parts.
Holes for #4-40 screws were drilled and tapped in 0.19
inch (4.8 mm) thick TORLON plaques. Screw pull-out
strength determined by ASTM D1761* appears in Table 27
Ultrasonic Inserts
Metal inserts can be imbedded in uncured TORLON parts
by ultrasonic Insertion. Inserts are installed rapidly with
strength comparable to that provided by molded-in techniques. A hole is molded slightly smaller than the insert.
The metal insert is brought in contact with the TORLON
part. Vibration in excess of 18 kHz is applied to the metal
insert, creating frictional heat which melts the plastic.
High strength is achieved if sufficient plastic flows around
knurls, threads, etc.
Other Mechanical Joining Techniques
Because post-cured TORLON parts are extremely tough,
some joining techniques will not be suitable. Expansion inserts are generally not recommended; however, each application should be considered on an individual basis.
Adhesive Choice
Elongation
%
9.5
6.6
Shear torque
in/lb
28.6
27.2
N/m
5,000
4,760
Tensile strength calculations were based on 0.0364 inch2 (0.235 cm2) cross
sectioned area. Torque tests were conducted by tightening the bolts on a
steel plate with steel washers and nuts. Maximum shear torque was
determined using a torque wrench graduated in inch-pounds.
Pull-out strength
Interference, or press fits, provide joints with good
strength at minimum cost. TORLON engineering polymer is
ideal for this joining technique due to its resistance to
creep. Diametral interference, actual service temperature, and load conditions should be evaluated to determine if stresses are within design limits.
TORLON poly(amide-imide) parts can be joined with commercial adhesives, extending design options. It is a good
practice to consult the adhesive supplier concerning the
requirements of your application.
N/mm2
125
127
Table 27
Interference Fits
psi
18,200
18,400
TORLON 4203L
TORLON 4275
TORLON 4301
*
lb
540
400
460
kg
240
180
200
Engagement
threads per hole
7.5
7.7
7.8
Crosshead speed was 0.1 inch (0.25 cm) per minute. The span between the
plaque and the screw holding fixture was 1.08 inches (2.7 cm).
TORLON Grade
TORLON 4203L, 5030, and 7130 are relatively easy to bond.
Bearing grades 4301, 4275, and 4347 have inherent lubricity, and are more difficult to bond. Table 28 compares the
shear strengths of these grades bonded with epoxy,
cyanoacrylate, and amide-imide adhesives.
Surface Preparation
Bonding surfaces should be free of contaminants, such as
oil, hydraulic fluid and dust. TORLON parts should be dried
for at least 24 hours at 300°F (149°C) In a desiccant oven
(thicker parts, over ¼ inch (6.3 mm), require longer drying
time) to dispel casual moisture prior to bonding. TORLON
surfaces should be mechanically abraded and solvent-wiped, or treated with a plasma arc to enhance
adhesion.
Adhesive Application
For adhesives other than amide-imide, follow the manufacturer’s directions. For amide-imide adhesive: coat each
of the mating surfaces with a thin, uniform film of the adhesive. Adhesive coated surfaces should be clamped under minimal pressure, approximately 0.25 psi (1.7 x 10-3
N/mm2) . The excess adhesive can be cleaned with
n-methyl pyrrol 1done (NMP).**
** Warning! NMP is a flammable organic solvent and the appropriate
handling procedures recommended by EPA, NIOSH, and OSHA should be
followed. Adequate ventilation is necessary when using solvents.
A variety of adhesives including amide-imide, epoxy, and
cyanoacrylate can be used to bond TORLON parts.
Cyanoacrylates have poor environmental resistance and
are not recommended. Silicone, acrylic, and urethane adhesives are generally not recommended unless environment conditions preclude other options.
– 44 –
Joining
Curing Procedure
Amide-imide adhesive should be cured in a vented,
air-circulating oven. The recommended cycle is 24 hours
at 73°F, 24 hours at 300°F, 2 hours at 400°F. The parts
should remain clamped until cooled to below 150°F (66°C).
Bond Strength of Various Adhesives
Commercial adhesives were used to bond TORLON parts.
The bonds were evaluated* for shear strength, which appears in Table 28.
Method of cure, handling, and working life of the adhesive
are rated in terms of “ease of use” Useful temperature
ranges appear in the manufacturers’ literature and will
vary with factors such as load and chemical environment.
Impact Strength of TORLON to TORLON Bonds
The impact strengths of bonded TORLON 4203L specimens
using the ASTM D256 (lzod impact) apparatus were measured in foot-pounds of force required to break the bond.
Epoxy bonds failed at impacts ranging from 0.6 to 14.6;
amide-imide specimens failed at 8.3 to 20 + amide-imide
40% SCF.
Bonding for High-Temperature Applications
Amide-imide adhesive provides high strength bonds at elevated temperature. At 350°F (1 77°C), amide-imide adhesive with 40% SCF withstands lap shear forces over 4,000
psi applied to TORLON 4203L/TORLON 4203L bonds. A
high-temperature epoxy failed at 750 psi under the same
conditions.
Table 28
Shear strength of TORLON to TORLON bonds
1
2
Epoxy
TORLON 4203L
TORLON 4301
TORLON 4275
TORLON 4347
TORLON 5030
TORLON 7130
Ease of use = easiest
Useful temperature range,
°F
°C
psi
6,000+
2,250
3,500
2,360
4,780
6,400+
N/mm2
41.4+
15.5
24.1
16.3
33.0
44.1+
2
- 67 to 160
- 55 to 71
Cyanoacrylate
psi
N/mm2
2,780
19.2
1,740
12.0
1,680
11.6
1,870
12.9
3,070
21.2
3,980
27.4
1
Amide-imide
psi
N/mm2
5,000+
34.5+
2,890
19.9
3,400
23.4
2,960
20.4
5,140
35.4
4,750
32.8
3
Amide-imide+40% SCF
psi
N/mm2
6,000+
41.4+
- 20 to 210
- 29 to 99
- 321 to 500
- 196 to 260
- 321 to 500
- 196 to 260
4
*
Post-cured TORLON bars, 2.5 x 0.5 x 0.12.5 inch (6.4 x 1.27 x 0.32 cm) were lightly abraded, wiped with acetone, then bonded with a 0.5 inch (1.3 cm) overlap. The
clamped parts were cured per adhesive manufacturer’s recommendations. After seven days at room temperature, bonds were pulled on an Instron® at a
crosshead speed of 0.05 inches per minute (0.13 cm per minute). If failure occurred outside the bond area, the process was repeated with progressively smaller
bonds areas, to a minimum overlap of 0.125 inch (0.32 cm) (in Tables 28 and 29, “+” denotes failure outside the bond area at 0.125 inch overlap).
1
Hysol EA 9330. Hysol is a trademark of Dexter Corporation.
2
CA 5000. Lord Corporation.
SCF is an Amide-Imide adhesive component available from Solvay Advanced Polymers Polymers, Inc.
– 45 –
Bonding TORLON parts to metal
TORLON and metal parts can be joined with adhesives.
With proper surface preparation and adhesive handling,
the resulting bonds will have high strength. In addition,
there will be minimal stress at the interface with temperature change. This is because TORLON resins, unlike many
other high temperature plastics, have expansion coefficients similar to those of metals.
As mentioned in the preceding section, bond strength depends on adhesive selection, and TORLON grade, as well
as proper technique in preparing and curing the bond.
Table 29 reports shear strength data for TORLON to aluminum and TORLON to steel bonds. Mechanical abrasion
alone may not be adequate for preparing steel
surfaces—chemical treatment of the steel is recommended when service temperature requires use of amide-imide adhesive.
Table 29
Shear strength* of TORLON to metal bonds
Shear strength—aluminum 2024 to TORLON bonds
TORLON 4203L
TORLON 4301
TORLON 4275
TORLON 4347
TORLON 5030
TORLON 7130
psi
4000
2500
2450
1100
3900
4000
Epoxy1
N/mm2
27.6
17.2
16.9
7.6
26.9
27.6
1
TORLON 4203L
TORLON 4301
TORLON 4275
TORLON 4347
TORLON 5030
TORLON 7130
Ease of use= easiest
Useful temperature range,
°F
°C
psi
3050
3700
3150
2450
4650
4550
Epoxy
N/mm2
21.0
25.5
21.7
16.9
32.1
31.4
psi
1350
1450
750
850
3250
3750
Cyanoacrylate2
N/mm2
9.3
10.0
5.2
5.9
22.4
25.9
psi
5050+
4950+
4350+
2800+
6050+
6400+
Amide-imide
N/mm2
34.8+
34.1+
30.0+
19.3+
41.7+
44.1+
Shear strength—cold rolled steel to TORLON bonds
Cyanoacrylate2
Amide-imide
psi
N/mm2
psi
N/mm2
2200
15.2
1450
10.0
2050
14.1
1850
12.7
2450
16.9
1900
13.1
2100
14.5
1400
9.7
2100
14.5
2400
16.5
2450
16.9
1100
7.6
Amide-imide+40% SCF
psi
N/mm2
4100+
28.3+
Amide-imide+40% SCF
psi
N/mm2
1900
13.8
2
1
3
4
- 67 to 160
-.55 to 71
- 20 to 210
- 29 to 99
- 321 to 500
- 196 to 260
- 321 to 500
- 196 to 260
*
The procedure was the same as noted in the preceding section. This test used TORLON bars 2.5 x 0.5 x 0.125 inches (6.35 x 1.27 x 0.32 cm); steel strips 2.5 x 0.5 x
0.125 inches cut from cold rolled steel, dull finished panel; and aluminum strips 2.5 x 0.5 x 0.125 inch cut from 2024 alloy panels.
1
Hysol EA 9330. Hysol is a trademark of Dexter Corporation.
2
CA 5000. Lord Corporation.
SCF is an Amide-Imide adhesive component available from Solvay Advanced Polymers
– 46 –
Guidelines for Machining TORLON Parts
Guidelines for Machining TORLON
Parts
Table 30
Guidelines for machining TORLON parts
Molded shapes and extruded bars manufactured from
TORLON poly(amide-imide) can be machined using the
same techniques normally used for machining mild steel
or acrylics. Machining parameters for several typical operations are presented in Table 30.
TORLON parts are dimensionally stable, and do not deflect
or yield as the cutting tool makes its pass. All TORLON
grades are very abrasive to standard tools, and high
speed tools should not be used.
Carbide-tipped tools may be used to machine TORLON
parts, but diamond-tipped or insert cutting tools are
strongly recommended. These tools will outlast carbide
tipped tools and provide a strong economic incentive for
production operations, despite a relatively high initial
cost. Thin sections or sharp corners must be worked with
care to prevent breakage and chipping. Damage to fragile
parts can be minimized by using shallow cuts during finishing operations. The use of mist coolants to cool the tool
tip as well as help remove chips or shavings from the
work surface is recommended. Air jets or vacuum can be
used to keep the work surface clean.
Parts machined from injection-molded blanks may have
built-in stresses. To minimize distortion, parts should be
machined symmetrically, to relieve opposing stresses.
Turning
Cutting speed, fpm
Feed, in/rev
Relief angle, degrees
Rake angle, degrees
Cutting depth, in
300-800
0.004-0.025
5-15
7-15
0.025
Circular Sawing
Cutting, fpm
Feed, in/rev
Set
Rake angle, degrees
6000-8000
fast & steady
15
slight
15
Milling
Cutting speed, fpm
Feed, in/rev
Rake angle, degrees
Cutting depth, in
500-800
0.006-0.035
5-15
7-15
0.035
Drilling
Cutting speed, rpm
Feed, in/rev
Point angle, degrees
300-800
0.003-0.015
0
118
Reaming
Slow speed, rpm
150
Machined Parts Should be Recurred.
Parts designed for friction and wear-intensive service, or
which will be subjected to harsh chemical environments
should be recurred after Machining to insure optimum
performance. If such a part has been machined to greater
than 116 inch (1.6 mm) depth, recurring is strongly
recommended.
– 47 –
General Procedures
Finishing
Flame/Arc Spraying
It is often necessary to mark or decorate TORLON parts
for appearance or functional purposes. The technique
should be considered early in the process of design, to
ensure that it will be compatible with the material and the
geometry of the part.
To enhance EMI shielding, flame erosion resistance, and
high velocity particle erosion resistance, TORLON parts
can be coated using flame or arc spraying techniques.
TORLON parts have been metallized using a thermal-spray
technique by TAFA Metallisations, Incorporated, Bow,
New Hampshire, and Metco, Incorporated, Westbury,
New York.
General Procedures
Prepare TORLON parts by removing surface contaminants. Usually, no pretreatment of TORLON parts is required-however, adhesion of the finish to the TORLON part
is enhanced by techniques such as etching or mechanical
abrasion.
Metallizing
Electroplating, flame spraying, plasma sputtering, and ion
plating techniques have been used successfully for
metallizing TORLON parts. Vacuum metallizing is not
recommended.
Electroplating
The electroplating procedure outlined below yields a uniform metal coating with good adhesion of two to four
pounds per linear inch (0.35-0.70 N/mm).
1. Etch – 4.3 percent (by weight) NaOH solution at 155 to
160°F (70°C) for six minutes.
2. Rinse – 180°F (82°C) deionized water for two to three
minutes.
3. Catalyst treat – Mac Dermid* D-34 at room
temperature for two minutes.
4. Activate – Mac Dermid D-45 at 120°F (49°C) for one
minute.
5. Electroless nickel coat – Mac Dermid at room
temperature for seven minutes.
6. Electroplate.
7. Dry at 220°F (104°C) for two hours.
Plasma Sputtering
Plasma (cathode) sputtering has been used successfully
to deposit vaporized metal on TORLON parts by Varian Associates, Palo Alto, California.
Ion Plating
TORLON parts have been ion-plated. According to Illinois
Tool Works, Incorporated, of Elgin, Illinois, their process
requires no base coat and produces metal coatings with
superior adhesion at a cost less than plasma sputtering.
Painting
TORLON parts can be painted using commercially available paints with conventional spraying, dipping, and
roller-coating techniques. Because TORLON poly(amide-imide) has such tremendous heat resistance, paints
can generally be cured by baking. The paint bake cycle
should start at 300°F (149°C) for 30 minutes to drive off casual moisture, then proceed as recommended by the paint
supplier.
*Mac Dermid Corporation, Waterbury, Connecticut
Technical Service
Our expert technical staff is ready to answer your questions related to designing, molding, finishing or testing
TORLON parts. We respect proprietary information and
will consult with you on a confidential basis.
The latest design, fabrication and testing equipment available to our service engineers supplements their years of
practical experience with applications of TORLON polymers. Using a computer-aided design workstation, our
-engineers can forecast the cost and performance of your
proposed part and offer suggestions for efficient molding.
Solvay Advanced Polymers can also provide rod, sheet,
film, plate, ball, disc, and tube stock shapes for making
prototype parts.
The availability of these services can be a tremendous
help as you evaluate TORLON poly(amide-imide) for your
engineering resin needs.
– 48 –
Technical Service
Metallizing
Whatever type of process you are considering, our personnel and facilities can help you achieve consistent
quality and more profitable products. Call us to discuss
your ideas.
– 49 –
Centrifugal Compressor Labyrinth
Seals
TORLON® poly(amide-imide) resins produce
labyrinth seals that are more corrosion
resistant than Aluminum and can be fitted to
smaller clearances. Smaller clearances mean
higher efficiency and greater through-put
without increasing energy input. Better
corrosion resistance means more productive
time between maintenance shutdowns.
Stock Shapes of TORLON Resin
TORLON® resins can be formed into
stock shapes useful for machining
prototypes by injection molding,
compression molding, or extrusion.
Shapes as large as 36 inches ( 900 mm)
in outside diameter by 6 inches (150
mm) long weighing 120 pounds (54 kg)
have been made.
Solvay Advanced Polymers, L.L.C.
4500 McGinnis Ferry Road
Alpharetta, Georgia 30005-3914 USA
Phone
+1.770.772.8200
Engineering polymers for high-performance applications
are developed at our Alpharetta, Georgia facility.
To learn more about our products and
services, please visit our website at
www.solvayadvancedpolymers.com
To our actual knowledge, the information contained herein is accurate as of the date of this document. However, neither Solvay Advanced Polymers, L.L.C. nor any of its affiliates makes any warranty, express or implied, or accepts any liability in connection with this information or its use. This information is for use by technically skilled persons at their own discretion and risk and does not relate to the use of this product in
combination with any other substance or any other process. This is not a license under any patent or other proprietary right. The user alone must finally determine suitability of any information or material for any
contemplated use, the manner of use and whether any patents are infringed.
T-49893
Copyright 2002, Solvay Advanced Polymers, L.L.C. All rights reserved
R 03/02

Torlon® Resins Engineering Data

Transcription

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