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DuPont Superstructural Web SeminarPUSHING BACK THE BARRIERS TO METAL REPLACEMENT
February 28, 2006
DuPont Superstructural Web SeminarPUSHING BACK THE BARRIERS TO METAL REPLACEMENT
The information and suggestions provided in this on-line seminar are based on data believed to be reliable, but the DuPont Company makes no warranties express or implied as to their accuracy and assumes no responsibility or liability arising out of its use by others. Further, the information and suggestions are not intended to substitute for any testing you may need to conduct to determine for yourself the suitability of a particular material for a particular purpose. DuPont makes no guarantee of results and assumes no obligation or liability in connection with the use of the information or suggestions provided in this seminar.
03/06/06
3
Pushing Back the Barriers to Metal Replacement
Presented by:
Bob TabaskoSuperstructural Market Development Leader
Gary KozielskiTechnical Consultant Superstructural Products
03/06/06
4
Agenda
Introduction to Superstructural1
Product Line Portfolio2
Key Properties3
Major Benefits Versus Metals & Other High Performance Polymers4
Applications5
Summary6
03/06/06
5
Family of resins with exceptional structural properties
Potential to provide: ultra high, consistent stiffness and strength capability outstanding impact performance excellent creep resistance structural performance at elevated temperatures
Based upon: Zytel® HTN high performance polyamide technology (greater than 35% glass reinforced) Long glass fiber reinforced Zytel® HTN and PA66 resins Rynite® glass-reinforced polyester
The Introduction to Superstructural
03/06/06
6
The Introduction to Superstructural
Less than 4% of metal applications have been converted to engineering plastics.
Superstructural grades open up a host of new metal replacement opportunities!
03/06/06
7
Agenda
Key Properties3
Major Benefits Versus Metals & Other High Performance Polymers4
Applications5
Summary6
Product Line Portfolio2
Introduction to Superstructural1
03/06/06
8
Pushing Back the Barriers to Metal Replacement
Unreinforced
Tens
ile S
tren
gth
Tensile Modulus
Reinforced StandardEP Resins
Steel
ZnAl
03/06/06
9
Pushing Back the Barriers to Metal Replacement
Unreinforced
Tens
ile S
tren
gth
Tensile Modulus
Reinforced StandardEP Resins
Steel
ZnAl
Future
Superstructural
03/06/06
10
Superstructural Key Grades
75LG60HSL60
75LG50HSL50
75LG40HSL40Long Length
70G60HSL60
Rynite® 555 (55% glass)54G50HSLR53G50HSLR50
Rynite® 54552G45HSL51G45HSL45Standard Fiber Length
Rynite®
PETZytel®PA66
Zytel®HTN54
Zytel®HTN53
Zytel®HTN52
Zytel®HTN51
Filler Level
Reinforcement Type
51LG50HSL
03/06/06
11
Key Features of the Zytel® HTN Product Families
Good toughness
High burst pressure and knit line strength
Retention of propertieswith moisture
Retains high level of stiffness up to 110°C
Water heated tools
PPA resin
Highest stiffness/strength at ambient temperatures
Good toughness
Outstanding surface finish
Water heated tools
Highest melting point and deflection temperature
Moldable in water heated tools
PPA resin
Outstanding retention of properties with moisture
Improved dimensionalstability
Retains high level of stiffness up to 140°C
PPA resin
HTN54 SeriesHTN53 SeriesHTN52 SeriesHTN51 Series
Superstructural • Ultra Stiff• High Strength• Excellent Creep Resistance
03/06/06
12
Agenda
Key Properties3
Major Benefits Versus Metals & Other High Performance Polymers4
Applications5
Summary6
Product Line Portfolio2
Introduction to Superstructural1
03/06/06
13
What is Zytel® HTN
Zytel® HTN high performance polyamides are partially aromatic nylons.
Most, but not all, Zytel® HTN resins fall within the narrower family of polymers known as PPA (Polyphthalamide), within which they offer perhaps the best combination of highest performance and ease of processing.
C- -C-]O O
[- NH-(CH 2 ) 6 - NH -
Aromatic Di-acid
n
Di-amine
03/06/06
14
What is Zytel® HTNDue to its Aromatic Ingredient, Parts Made With Zytel® HTN Have Excellent Chemical Resistance, and High Temperature Performance
Polyamide
Aliphatic Aromatic (Partially) Aromatic (Partially) PPA
Aromatic (Fully) Aramid
0% Less Than 55% 55% or More 100%
AromaticDi-Acids
Zytel® PA66 Zytel® PA6 Zytel® PA612
KEVLAR®
NOMEX®
HTN51HTN52HTN54Other PPAs
HTN53PAMXD6PA66 + PA6I/6T
Examples:
03/06/06
15
Long Fiber Reinforced Thermoplastics
Superstructural: LFRTs
Fiber length in granules—12 mm
Fiber length in molded parts are typically 3–4 mm versus 0.3 mm for standard glass fiber resins
Component design plus processing conditions govern average fiber length and therefore part performance
Knit line strength of LFRTs may also be an issue for certain designs
Specific guidelines are available from DuPont for both of these points
03/06/06
16
Ultra High Strength and StiffnessSt
ress
at B
reak
(MPa
)
ISO
527
Tensile Modulus DAM (GPa) ISO 527
260
240
220
200
180
160
140
120
100
8 10 12 14 16 18 20
PA46 50% GF PA66 43% GFPPS 40% GF
PPS 50% Long Glass
PP 50% Long glass
PBT 50% GF
Glass fiber reinforced engineering polymers Polyamides conditioned to 50% RH
03/06/06
17
Ultra High Strength and StiffnessSt
ress
at B
reak
(MPa
)
ISO
527
Tensile Modulus DAM (GPa) ISO 527
260
240
220
200
180
160
140
120
100
8 10 12 14 16 18 20
PA46 50% GF PA66 43% GFPPS 40% GF
PPS 50% Long Glass
PP 50% Long glass
PBT 50% GF
Glass fiber reinforced engineering polymers Polyamides conditioned to 50% RH
DuPont EP Superstructural standard glass fiber reinforced products Zytel® HTN51G45HSL
Zytel® HTN53G50HSLR
Zytel® HTN52G45HSL
Zytel® HTN54G50HSLR
Rynite® 545Zytel® 70G60HSLRynite® 555
03/06/06
18
Ultra High Strength and StiffnessSt
ress
at B
reak
(MPa
)
IS
O 5
27
Tensile Modulus DAM (GPa) ISO 527
260
240
220
200
180
160
140
120
100
8 10 12 14 16 18 20
PA46 50% GF PA66 43% GFPPS 40% GF
PPS 50% Long Glass
PP 50% Long glass
PBT 50% GF
Glass fiber reinforced engineering polymers Polyamides conditioned to 50% RH
DuPont EP Superstructural standard glass fiber reinforced products Zytel® HTN51G45HSL
Zytel® HTN53G50HSLR
Zytel® HTN52G45HSLZytel® HTN54G50HSLR
Rynite® 545Zytel® 70G60HSL Rynite® 555
DuPont EP Superstructural long glass fiber reinforced products
Zytel® 75LG40HSL
Zytel® 75LG50HSL
Zytel® HTN51LG50HSL
Zytel® 75LG60HSL
03/06/06
19
Long Glass—High Notched Impact Strength and ModulusN
otch
ed C
harp
y Im
pact
Str
engt
h (k
J/m
2 )
ISO
179
Tensile Modulus (GPa) ISO 527
70
60
50
40
30
20
10
0
Polyamides conditioned to 50% RHGlass fiber reinforced engineering polymers
DuPont EP Superstructural standard glass fiber reinforced products
PA46 50% GF
PA66 43% GF
PPS 40%GF
PP 50% Long glass
Zytel® HTN51G45HSL
Zytel® HTN53G50HSLR
Zytel® HTN54G50HSLRRynite® 545
Zytel® 70G60HSL
Rynite® 555
6 10 12 14 16 18 208
03/06/06
20
Long Glass—High Notched Impact Strength and ModulusN
otch
ed C
harp
y Im
pact
Str
engt
h (k
J/m
2 )
ISO
179
Tensile Modulus (GPa) ISO 527
70
60
50
40
30
20
10
0
6 10 12 14 16 18 20
Polyamides conditioned to 50% RH
8
PA46 50% GF
PA66 43% GF
PPS 40%GF
PP 50% Long glass
Zytel® HTN 51G45HSL
Zytel® HTN53G50HSLR
Zytel® HTN54G50HSLRRynite® 545
Zytel® 70G60HSL
Rynite® 555
Glass fiber reinforced engineering polymers
DuPont EP Superstructural standard glass fiber reinforced products
DuPont EP Superstructural long glass fiber reinforced products
Zytel® 75LG40HSL
Zytel® 75LG50HSL
Zytel® 75LG60HSL
Zytel® HTN51LG50HSL
03/06/06
21
Long Glass—Resins Increase Multiaxial Impact PerformanceZytel® Long Glass resins not only offer higher drop weight impact and notched impact resistance, but the nature of the break is more contained
0
5
10
15
20
25
PA66 50% GR BK Zytel® 75LG50L NC010
Energy to Max Load Total Energy
Joul
es
PA66 50% GR BK Zytel® 75LG50L NC010
DAMISO 6633 mm Disc
03/06/06
22
Benefits Through Mechanical Properties
Zytel® HTN Superstructural grades provide an excellent balance of strength, stiffness and impact performance compared to other glass fiber reinforced polyamides. Very low moisture effects give a major advantage…
Stress at Break (MPa) Tensile Modulus (GPa)
0
50
100
150
200
250
300
HTN51G45HSL PA66 43%GR HTN51LG50HSL PA46 50% GR
DAM 50% RH
0
2
4
6
8
10
12
14
16
18
20
HTN51G45HSL PA66 43%GR HTN51LG50HSL PA46 50% GR
DAM 50% RH
ISO 527
03/06/06
23
Extending Temperature Extremes
Long glass fiber increases the deflection temperature, allowing higher loads as temperatures heat up.
235
240
245
250
255
260
265
270
275
280
285Standard Glass Long Glass
DTU
L, ºC
I
SO
75
PA66 50% GR
Zytel® 75LG50HSL
HTN51G45HSL
HTN51LG50HSL
03/06/06
24
Agenda
Key Properties3
Major Benefits Versus Metals & Other High Performance Polymers4
Applications5
Summary6
Product Line Portfolio2
Introduction to Superstructural1
03/06/06
25
The Superstructural family offers a superb combination of stiffness, strength and impact resistance coupled with specific grades that are able to deliver a high temperature capability.
Superstructural: Key Benefits
They Can Provide The opportunity to enjoy the benefits of replacing metals in high performance components
that were previously unable to be made in standard engineering polymers
The possibility of producing plastic components with superior performance or alternatively with thinner section thereby reducing total cost and weight of parts
We will look at these areas more closely…
03/06/06
26
Pushing Back the Barriers to Metal Replacement
DuPont Superstructural gradesoffer many major benefits versus metals.
Let’s remember the key advantages...
03/06/06
27
Major Weight Savings Opportunities
Lighter weight provides savings in many different ways:
• Easier handling of parts• Reduced shipping costs• Automotive fuel efficiency
COPPER
BRASS
STEEL
CAST IRON
DIECAST ZINC and ZA ALLOYS
ALUMINUM ALLOYS
MAGNESIUM ALLOYS
SUPERSTRUCTURAL POLYMERS
10
9
8
7
6
5
4
3
2
0
1D
ensi
ty (g
/cc)
Incr
easi
ng w
eigh
t per
com
pone
nt
03/06/06
28
Benefits Through Light Weight Strength
Specific Tensile Strength (MPa/s.g.)
0 50 100 150 200
Zinc
Mild Steel
Aluminum Alloy
Magnesium Alloy
Superstructural Polymers
versus Aluminum = >40%
weight savings with
comparable strength !
up to 163
133
95
52
34
03/06/06
29
Time and Cost Saving Through Reduced Number of Processing Steps
Diecasting
Metal Ingots
Meltdown - cold chamber
MoldingFinishing
Painting
Finished part
6 Steps6 steps
Granules
Injection
Molding
Finished Part
Injection molding
Only 3 Steps
Sheet metal construction
Sheet metal
Stamping
DrillingCuttingBending
Assembly
Painting
Finished part
6 Steps
03/06/06
30
Beware: when replacement costs of diecast tools are amortized into your part cost, the expense can really add up!
Cost Savings Through Much Longer Average Tool Life
200
400
600
800
1,000
1,200
Num
ber o
f Sho
ts (k
)
150 k
Aluminum
300 k
Magnesium
450 k
Zinc
1000 k
DuPont Superstructural
Engineering Polymers
03/06/06
31
Opportunity for cost saving and functional benefits through part integration
Other Major Benefits versus Metals
Potential for highly innovative new designs
Higher corrosion resistance
Better surface finish with integral colors
03/06/06
32
Other Major Benefits versus Other High Performance Polymers
DuPont Superstructural grades offer key benefits over some other polymers that you may consider...
03/06/06
33
Zytel® HTN53G50HSLR versus PAMXD6
Components with much better toughness and overall balance of properties
Opportunity for reduced volume cost
Reduced processing costs
Reduced cycle time leads to higher production rates
Significantly better impact and elongation to break values
Lower density (2.5% with 50% glass level)
Mold tool temperature of 90°C compared to 140°C plus
Less flash
Faster set up (crystallization rate)
Versus PAMXD6(Polyarylamide)
Customer BenefitsHTN53 Series Advantages
03/06/06
34
Zytel® HTN54 series versus other PPA Resins
Components with greater durability in high abuse situations
Easier molding and potential for reduced cost
Higher overall toughness (impact and elongation to break)
Water heated mold capability
Versus Other PPA Resins
Customer BenefitsHTN54 Series Advantages
03/06/06
35
Zytel® LFRTs versus Long Fiber Reinforced PP
Opportunity to have higher performance parts or thinner section components with same performance
Components with greater durability in high abuse situations or new markets
Parts with extended performance capability or opportunity to open up new markets
Ability to develop components for more demanding environments.Greater reliability of part performance
Significantly higher strength (>70% increase)
Much higher notched impact strength (>65%increase)
Higher stiffness particularly at elevated temperatures
Vastly improved thermal properties (DTUL at 1.8 MPa for 75LG50HSL is 260°C versus 160°C for Long Fiber PP)
Versus Long FiberReinforced PP
Customer BenefitsZytel® LFTR Advantages
03/06/06
36
Agenda
Key Properties3
Major Benefits Versus Metals & Other High Performance Polymers4
Applications5
Summary6
Product Line Portfolio2
Introduction to Superstructural1
03/06/06
37
Applications
The benefits of DuPont Superstructural products in action...
03/06/06
38
Tractor Hinge—Zytel® HTN53
•High rigidity, impact resistance and tensile strength
•Lower cost versus aluminum
03/06/06
39
Brake Booster—Zytel® HTN51
•High strength and low warp
•Lighter weight due to reduction in wall thickness (60% lighter than thermoset)
03/06/06
40
Spline for Auto Arm Rest Retractor Mechanism Zytel® HTN53
• The spline can be subject to high loads and abuse situations
• Previously made from machined diecast metal—heavy and costly
• Zytel® HTN53 series offers high modulus, strength and very good impact properties
• Lighter weight and lower cost than metals, and the parts require no finishing
03/06/06
41
Structural Parts for Mobile Telephones Zytel® HTN53
• The main frame of a mobile phone is required to hold the sophisticated electronics firmly in place, protect them if dropped, be dimensionally stable and resist exposure to household chemicals
• Zytel® HTN53 offers high stiffness, very good impact resistance, and outstanding surface finish.
• Zytel® HTN53 can be molded to close tolerances using water heated molds
03/06/06
42
Windowlift Motor Gear Housing Zytel® HTN51
•Previously cast aluminum
•Weighs 30% less than cast aluminum housing
•Higher efficiency
•Excellent retention of stiffness and strength at elevated temperatures, chemical resistance, low warpage and low shrinkage
03/06/06
43
Boat Propeller—Rynite® 555
The stiffness and strength of Rynite® 555 is a key factor in limiting blade deflection and preventing deformation during fast starts and high-speed running.
•Higher performance
•Cost advantage
•No corrosion
•Engine protection
•Easy mounting
03/06/06
44
Agenda
Introduction to Superstructural1
Product Line Portfolio2
Key Properties3
Major Benefits Versus Other Plastics4
Applications5
Summary6
03/06/06
45
Outstanding Strength Rigidity Toughness High Temperature Capability
Allowing you to enjoy the benefits of Polymers in highly demanding application areas
weight saving, anti-corrosion, part cost, colors, integration…
New Superstructural…
Pushing Back the Barriers to Metal Replacement!
Summary
03/06/06
46
Thank you for joining us today.Please send in any questions using the Q&A function.
We will be answering questions for the rest of the hour. Depending on demand, we may not be able to answer your question straight away. All questions will be logged and any questions unanswered at the end of the session will be followed-up via email.Alternatively, please contact your local DuPont representative or log on to plastics.dupont.com and click on the Contact Us button.
For questions about our products and how to use them, call us at the following numbers:800-441-0575 or International 302-999-4592
Or visit us at: plastics.dupont.com
Copyright © 2006 DuPont or its affiliates. All rights reserved. The DuPont Oval Logo, DuPont™, The miracles of science™, Rynite®, Zytel®, NOMEX®, and KEVLAR® are registered trademarks or trademarks of DuPont or its affiliates.